Dodge - Neon - Workshop Manual - 2003 - 2003

Factory Workshop Manual Make Dodge Model Neon Engine and year L4-2.0L VIN F HO (2003) 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Alarm Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 12 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Alarm Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 18 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations Fig.9 Sentry Key Immobilizer Module (SKIM) Location Sentry Key Immobilizer Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 21 Alarm Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 22 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 23 Sentry Key Immobilizer Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 24 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE (SKIM) Fig.13 Sentry Key Immobilizer Module Fig.14 Sentry Key Immobilizer Module Location The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the instrument cluster, and the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique "Secret Key" code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The "Secret Key" code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the "Secret Key" code can be restored from the PCM by following the SKIM replacement procedure found in the DRB III scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original "Secret Key" code can not be recovered, new ignition keys will be required. The DRB III scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 25 secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the PCM during initialization. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an "invalid key" message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is "invalid key." Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. The SKIM also sends indicator light status messages to the instrument cluster to tell that module how to operate the light. This may consist of turning the light ON for a three (3) second bulb test when the ignition switch is first turned to the ON position. It is also the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement Alarm Module: Service and Repair Sentry Key Immobilizer Module Replacement REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Removal. 3. Remove the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Removal. Fig.15 Sentry Key Immobilizer Module (SKIM) Remove/Install 4. Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). 5. Remove the two screws securing the SKIM to the top of the steering column. 6. Rotate the SKIM and its mounting bracket upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKIM from the vehicle. INSTALLATION NOTE: If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/SENTRY KEY IMMOBILIZER MODULE STANDARD PROCEDURE). 1. Place the SKIM into position. 2. Rotate the SKIM and its mounting bracket downwards and then to the side towards the steering column. 3. Install the two screws securing the SKIM to the top of the steering column. 4. Engage the steering column wire harness to the Sentry Key Immobilizer Module (SKIM). 5. Install the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Installation. 6. Install the Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Installation. 7. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 28 Alarm Module: Service and Repair Programming the Sentry Key Immobilizer Module PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. 1. Turn the ignition on (transmission in park/neutral). 2. Use the DRBIII and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select SKIM MODULE REPLACEMENT (GASOLINE). 4. Program the vehicle four-digit PIN into the SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select UPDATE VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the VIN (the PCM will send the VIN to the SKIM). 8. The DRBIII will ask if you want to transfer the secret key. Select ENTER to transfer secret key from the PCM. This will ensure the current vehicle ignition keys will still operate the SKIS system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 29 Alarm Module: Service and Repair Programming Ignition Keys to the Sentry Key Immobilizer Module PROGRAMMING IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE 1. Turn the ignition on (transmission in Park / Neutral). 2. Use the DRBIII and select THEFT ALARM, SKIM, then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEYS. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM AT ONE TIME. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRBIII will display one of the following messages: Programming Not Attempted - The DRBIII attempts to read the programmed key status and there are no keys programmed in the SKIM memory. Programming Key Failed - (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done - SKIM transponder ID memory is full. 1. Obtain ignition keys to be programmed from customer (8 keys maximum) 2. Using the DRBIII, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS 3. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 30 Alarm Module: Service and Repair Sentry Key Immobilizer System Initialization The Sentry Key Immobilizer System (SKIS) initialization should be performed following a Sentry Key Immobilizer Module (SKIM) replacement. It can be summarized as follows: 1. Obtain the vehicle's unique four-digit PIN assigned to its original SKIM from the vehicle owner, the vehicle's invoice, or from Chrysler's Customer Center. 2. Using a DRB III scan tool, select "Theft Alarm," "SKIM," "Miscellaneous," and then "SKIM Module Replaced." a. Enter Secured Access Mode using the unique four-digit PIN. b. Program the vehicle's VIN number into the SKIM's memory. c. Program the country code into the SKIM's memory (for North America, choose US or domestic). d. The vehicle's unique Secret Key data will be retrieved from the PCM automatically. If this data is corrupt or not present, you will be prompted to cut new keys for this vehicle. 3. Program all customer keys into the SKIM's memory. This process will require that the SKIM to be in the Secured Access Mode. The PIN must be entered into the DRB III scan tool before the SKIM will enter the Secured Access Mode. Once entered, Secured Access Mode shall be active until 60 seconds after the last command requiring secured access was received and acknowledged. Two exceptions to this rule are: - When you have used the 'erase all keys' command OR - When you have just programmed a new key. If either of these functions are performed successfully while in the Secured Access Mode, this mode will be exited immediately following the function. NOTE: If a PCM is replaced, the unique 'Secret Key' data must be transferred from the SKIM to the new PCM using the PCM replacement procedure. This procedure requires the Secured Access Mode as well and can be found in the DRB III scan tool. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 31 Alarm Module: Service and Repair PCM/SKIM Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 32 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 41 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 47 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 50 Keyless Entry Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 51 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 52 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 53 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 54 Remote Keyless Entry Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 55 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE There are 2 Remote Keyless Entry Modules for the 2002 module year, premium and base. The base module is for a vehicle with power door locks only. The base module performs the same functions that the premium module does but has no provisions for Vehicle Theft Security System (VTSS) or Remote Keyless Entry. Both modules communicate with other modules via the PCI bus circuit. The module monitors the Airbag Control Module messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message, along with the verification that the ignition is on, it will provide the "enhanced accident response feature". This feature will cause the module to unlock all doors and the instrument cluster to turn the courtesy lamps ON. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message and receive body style information. The Base module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the driver or passenger (BUX) cylinder lock switch. The premium module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the RKE transmitter. Two RKE transmitters are supplied with a premium equipped vehicle but a total of 4 can be programmed to the module. Horn chirp on a premium equipped vehicle is customer programmable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 56 Keyless Entry Module: Testing and Inspection For procedures on diagnosing and testing the RKE Module's RKE functions, refer to the proper Body Diagnostic Procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 66 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 72 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 75 Keyless Entry Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 76 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 77 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 78 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 79 Remote Keyless Entry Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 80 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE There are 2 Remote Keyless Entry Modules for the 2002 module year, premium and base. The base module is for a vehicle with power door locks only. The base module performs the same functions that the premium module does but has no provisions for Vehicle Theft Security System (VTSS) or Remote Keyless Entry. Both modules communicate with other modules via the PCI bus circuit. The module monitors the Airbag Control Module messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message, along with the verification that the ignition is on, it will provide the "enhanced accident response feature". This feature will cause the module to unlock all doors and the instrument cluster to turn the courtesy lamps ON. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message and receive body style information. The Base module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the driver or passenger (BUX) cylinder lock switch. The premium module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the RKE transmitter. Two RKE transmitters are supplied with a premium equipped vehicle but a total of 4 can be programmed to the module. Horn chirp on a premium equipped vehicle is customer programmable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 81 Keyless Entry Module: Testing and Inspection For procedures on diagnosing and testing the RKE Module's RKE functions, refer to the proper Body Diagnostic Procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module Sunroof / Moonroof Module: Service and Repair Sunroof Module REMOVAL Fig. 1 Sunroof Components 1. Remove sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Disengage front door weatherstrip from headliner, pull headliner down to access control unit. 2. Disconnect wire connector from control unit. 3. Slide control unit up and forward and remove. INSTALLATION 1. Place sunroof control unit into position. 2. Lock control unit into position. 3. Connect wire connector to control unit. 4. Install sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Engage front door weatherstrip to headliner. 5. Cycle sunroof to the full open position. 6. Ensure sunroof adjustment. Refer to Sunroof Glass Adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 87 Sunroof / Moonroof Module: Service and Repair Sunroof Module Assembly REMOVAL 1. Close glass panel, if possible 2. Remove A-pillar trim. 3. Remove upper B-pillar and C-pillar trim. Fig. 1 Sunroof Components 4. Remove sunroof welt. 5. Remove the switch. 6. Detach fastener from headlinder bracket to the front beam. 7. Remove all assist handles. 8. Remove sun visors. 9. Remove headlining and disconnect the dome lamp connector. 10. Disconnect sunroof motor wiring connector. 11. Disconnect drain tubes. 12. Remove fasteners attaching sunroof module to vehicle roof. 13. With the aid of a helper, remove sunroof module from roof. 14. Remove sunroof module from vehicle. INSTALLATION 1. With the aid of a helper, position sunroof module in vehicle. 2. Install fasteners attaching sunroof module to vehicle roof and support braces. Tighten all fasteners to 5 Nm (44 in. lbs.), starting from the front and working rearward and then the motor bracket. 3. Connect drain tubes. 4. Connect sunroof motor wiring connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 88 5. Headliner in position connect dome lamp wire connector. Install headlining. 6. Install the fastener from the headliner bracket to front beam. 7. Install switch. 8. Install sunroof welt. 9. Install B-pillar and C-pillar trim. 10. Install A-pillar trim. 11. Install sun visors. 12. Install all assist handles. 13. Install sunroof sunshade. 14. Install sunroof glass panel. 15. Cycle glass panel open and close. 16. Ensure glass adjustment, refer to Glass Adjustment procedure 17. Verify correct operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig.1 Integrated Control Unit (ICU) The CAB is mounted to the ICU as part of the Integrated Control Unit (ICU). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 93 Controller Antilock Brake Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 94 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. Fig.3 CAB Mounting 3. Disconnect pump/motor connector from CAB. 4. Remove four screws securing CAB to HCU half of ICU. Remove CAB from HCU. 5. Pull outward on CAB connector lock and disconnect 24-way wiring connector. Remove CAB from vehicle. INSTALLATION 1. Connect 24-way wiring connector to CAB and push in connector lock. 2. Align CAB with HCU half of ICU, then slide CAB up over HCU valves. Install four CAB mounting screws. Tighten mounting screws to 2 Nm (17 in. lbs.) torque. 3. Connect pump/motor connector. 4. Lower vehicle. 5. Connect battery negative cable. 6. Connect DRBIII to vehicle to initialize system. Check and clear any faults. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 99 Radiator Fan Relays Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 100 Radiator Fan High Relay (1.6L/2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 101 Radiator Cooling Fan Motor Relay: Testing and Inspection Test 1 - 4 Test 5 SYMPTOM CHECKING RADIATOR FAN RELAY OUTPUT POSSIBLE CAUSES - Radiator fan relay operation - Ground circuit open - Radiator fan motor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 102 - Fused B+ circuit - Radiator fan relay output circuit - Radiator fan relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 107 A/C Compressor Clutch Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 108 Compressor Clutch Relay: Diagrams Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 109 A/C Compressor Clutch Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 110 Compressor Clutch Relay: Description and Operation Fig.6 A/C Compressor Clutch Relay A/C COMPRESSOR CLUTCH RELAY The A/C compressor clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for A/C compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the A/C compressor clutch relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The factory-installed A/C compressor clutch relay cannot be adjusted or repaired. If the relay is damaged or faulty it must be replaced. The A/C compressor clutch relay is an electromechanical switch that uses a low current input from the Powertrain Control Module (PCM) to control the high current output to the Compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the PDC. The inputs and outputs of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 111 the A/C compressor clutch relay include: The common feed terminal (30) receives a battery current input from a fuse in the PDC through a fused B(+) circuit at all times. - The coil ground terminal (85) receives a ground input from the PCM through the A/C compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from a fuse in the fuse block module through a fused ignition switch output (run-start) circuit only when the ignition switch is in the ON or Start positions. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the A/C compressor clutch relay output circuit only when the A/C compressor clutch relay coil is energized. The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C compressor clutch relay coil is de-energized. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 112 Compressor Clutch Relay: Testing and Inspection Test 1 - 4 Test 5 SYMPTOM CHECKING THE A/C RELAY OUTPUT POSSIBLE CAUSES - A/C clutch relay operation - Ground circuit open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 113 - A/C clutch - Fused B+ circuit - A/C clutch output circuit - A/C clutch relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 114 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for A/C compressor clutch relay identification and location. 4. Remove the A/C compressor clutch relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper A/C compressor clutch relay location. 2. Position the A/C compressor clutch relay in the proper receptacle in the PDC. 3. Align the A/C compressor clutch relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the A/C compressor clutch relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Alignment Control Module > Component Information > Diagrams Headlamp Alignment Control Module: Diagrams Left Lavelier Module (Export) Right Lavalier Module (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 122 Horn Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 123 Horn Relay: Testing and Inspection 1. Remove horn relay from Power Distribution Center (PDC). 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/HORN - DIAGNOSIS AND TESTING). 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. Fig. 2 Horn Relay 5. Click relay for 70 to 75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 124 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center cover and locate the horn relay. 3. Remove the horn relay. INSTALLATION 1. Insert the horn relay into the Power Distribution Center (PDC). 2. Install the PDC cover 3. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 130 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 131 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 132 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 133 Relay Box: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 134 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 137 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 138 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 139 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 140 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 141 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center Relay Box: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center > Page 144 Relay Box: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Page 145 Relay Box: Service and Repair POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 156 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 157 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 158 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 159 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 160 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 161 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 162 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 163 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 164 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 166 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 167 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 168 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 169 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 170 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 171 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 173 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 174 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 175 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Body Control Module: Electrical Diagrams Airbag System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Audio System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 CD Changer Compass/Temperature Mirror Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Exterior Lighting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Instrument Cluster Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 Interior Lighting Power Door Locks/RKE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 Vehicle Communication Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 186 Body Control Module: Vehicle Damage Warnings Electrical Testing 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description Identification Of System The vehicle systems that are part of the "body" system are: - Airbag System - Audio - Compass/Temperature Mirror - Instrument Cluster - Interior Lighting - Power Door Locks/Remote Keyless Entry - Vehicle Communications - Vehicle Theft Security System System Description The body system on the 2003 PL consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Vehicle Communication See: Functional Operation/Vehicle Communication of this general information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 189 Body Control Module: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. DRIVER AIRBAG (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation, The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 190 PASSENGER AIRBAG (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). WARNING: REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) They are located on the left and right B-post. The SIACM perform self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ACM once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned on. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. SEAT AIRBAGS The Left and Right seat airbag modules are located in the outboard end of the front seat backs. The airbag module contains a bag, an inflator (a small canister of highly compressed argon gas) and a mounting bracket. The seat airbag module cannot be repaired and must be replaced if deployed or in any way damaged. When supplied with the proper electrical signal the inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. NOTE: It will be necessary to remove the seat back trim to gain access to the seat airbag module connector when diagnosing the seat airbag system. WARNING: THE SEAT AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SPECIAL TOOLS Some airbag diagnostic tests use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 191 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: * Erase the stored codes * Place the ignition in the Run position * Wiggle the wire harness and connectors * Rotate the steering wheel from stop to stop * Recheck for active codes periodically as you work through the system. Audio System AUDIO SYSTEM The audio system on the 2003 PL consists of a radio that communicates over the PCI bus. The speakers are located in the instrument panel, the front doors and the rear "D" pillars. The instrument panel speakers are a tweeter type speaker for high frequency. The front door speakers are a woofer/midrange type speaker. The rear "D" pillar speakers are a full range type speaker. If one of the speaker circuits experiences a short, the other speakers on that output channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which the DRB III(R) can display. The in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect , such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in the chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 192 disc in that chamber. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Compass/Temperature Mirror COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 193 Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 194 magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 195 If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Exterior Lighting EXTERIOR LIGHTING The Headlamps are controlled by the Instrument Cluster. The Instrument Cluster is also referred to as a "Smart Cluster". It receives and sends messages to other modules through the PCI BUS circuit. The Headlamps are wired through the cluster and then go to the Fuse Block to the lamps. Each Headlamp has an independent fuse located in the Fuse Block. For vehicles equipped with Daytime Running Lamps, the DRL Module is integrated with the Instrument Cluster. Interior Lighting INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. Some of the features that it controls are the courtesy lamps, chime, and all instrument illumination. It receives and sends messages to other modules via the PCI bus circuit. The front turn signals are wired through the cluster and then go to the front lamps. For vehicles equipped with Daytime Running Lamps, the DRL module is built into the cluster. Power Door Locks/Remote Keyless Entry REMOTE KEYLESS ENTRY MODULE The Remote Keyless Entry module controls the Power Door Locks and the Vehicle Theft Security System (VTSS). It also wakes up the Instrument Cluster to turn on the illuminated entry when it senses a signal from the RKE transmitter. The module communicates with other modules via the PCI bus circuit. The RKE module monitors the Occupant Restraint Controller messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message along with the verification that the ignition is on and the vehicle speed is zero, it will provide the "enhanced accident response feature". This feature will cause the module to unlock-all doors immediately and the instrument cluster to turn the courtesy lamps on when the vehicle reaches 0 mph. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message, and receive body style information. Two transmitters are supplied with the vehicle but a total of 4 can be programmed to the module. The horn chirp on vehicle lock command is customer programmable. To limit the amount of battery drain during storage, the IOD fuse may be removed. VEHICLE THEFT SECURITY SYSTEM When the VTSS is armed, it will monitor the ignition switch status, ajar switches for the vehicle doors and decklid. Also monitored is a decklid security switch (knockout) for the cylinder lock. If the alarm is tripped, it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 196 Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, by using the driver door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of an open decklid security switch sense circuit. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with the driver door cylinder lock. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. VEHICLE THEFT SECURITY SYSTEM (Export Only) When the VTSS is armed, it Will monitor the interior of the vehicle for movement via an intrusion sensor (if equipped), the ignition switch status, ajar switches for the vehicle doors, decklid and hood. Vehicles without an intrusion sensor will have a decklid security switch (knockout) which will also be monitored. If the alarm is tripped, it will sound the vehicles horn or a battery backed siren for vehicles equipped with the intrusion sensor, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, or by using either door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of the hood ajar circuit being shorted (hood opened) or the decklid security switch circuit being open (if equipped). Defeating the intrusion sensor feature for vehicles so equipped can be done by three additional lock request to the RKE module within 5 seconds. Disarming is done by either a RKE unlock or turning the ignition on with a valid Sentry key. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. Vehicle Communication VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2003 PL: - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio (If equipped) - CD Changer (If equipped) - Compass/Temperature Mirror (If equipped) - Remote Keyless Entry Module (If equipped) - Sentry Key Immobilizer Module (If equipped) - Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 197 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III(R) lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the diagram for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at the module, or an open battery or ground circuit to the affected Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - No response received from any module on the PCI bus (except PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 198 Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III(R) may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Airbag Indicator On Without ACM Trouble Codes Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACM TROUBLE CODES POSSIBLE CAUSES - Airbag indicator on without ACM trouble codes - Instrument cluster problems No Response From Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 201 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 202 Test 3 - 4 SYMPTOM NO RESPONSE FROM ACM POSSIBLE CAUSES - Checking for voltage at ACM - Ground circuit open - PCI bus circuit open - Airbag control module AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 203 POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 204 CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 205 Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure No Response From Radio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 206 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 207 Test 4 - 6 SYMPTOM NO RESPONSE FROM RADIO POSSIBLE CAUSES - No response from radio - Open fused ignition switch output circuit - Open fused B+ circuit - Radio ground circuit open - Open PCI bus circuit - Radio Pause/Play Switch Inoperative Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 208 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 209 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 210 - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Compass/Temperature Mirror Does Calibrate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 211 Test 1 Test 2 SYMPTOM COMPASS/TEMPERATURE MIRROR DOES CALIBRATE POSSIBLE CAUSES - Calibration procedure - Compass/temperature mirror Compass/Temperature Mirror Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 212 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 213 Test 4 - 6 SYMPTOM COMPASS/TEMPERATURE MIRROR INOPERATIVE POSSIBLE CAUSES - No response - PCI bus - compass - Fused B(+) circuit short to ground - Fused B(+) circuit open - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Ground circuit open - Compass/temperature mirror High Beam Headlamps Will Not Turn Off Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 214 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Dimmer switch high beam output circuit short to voltage - Instrument cluster - Multifunction switch High Beam Headlamps Will Not Turn On Test 1 - 4 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 215 Test 5 - 7 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Open fused B+ - Dimmer switch low beam output circuit short to ground - Dimmer switch high beam output circuit short to ground - Open fuse - Dimmer switch low beam output circuit open - Instrument cluster - Multifunction switch Low Beam Headlamps Will Not Turn Off Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 216 Test 1 - 3 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Multifunction switch - Dimmer switch low beam output circuit short to voltage - Fuse block - Instrument cluster Low Beam Headlamps Will Not Turn On Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 217 Test 1 - 4 Test 5 - 6 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Multifunction switch - Fuse block - Dimmer switch low beam output circuit open - Instrument cluster - Open fused B+ to fuse block - Fused B+ circuit short to ground - B+ circuit breaker 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 218 All Gauges Inoperative Test 1 - 4 Test 5 - 6 SYMPTOM ALL GAUGES INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 219 POSSIBLE CAUSES - No response - PCI bus - No response - PCI bus - powertrain control module - No response - PCI bus - instrument cluster - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Instrument cluster ground circuit open - Instrument cluster Any or All Gauge Pointer(s) On Wrong Side of Stop Test 1 SYMPTOM ANY OR ALL GAUGE POINTER(S) ON WRONG SIDE OF STOP POSSIBLE CAUSES - Instrument cluster Any PCI Bus Indicator Inoperative Test 1 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 220 POSSIBLE CAUSES - LED defective - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 221 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake warning indicator circuit short to ground - Red brake warning indicator driver circuit short to ground - Park brake switch - Brake fluid level switch - Instrument cluster - Powertrain control module Brake Warning Indicator Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 222 Test 4 - 7 Test 8 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 223 POSSIBLE CAUSES - Brake warning indicator circuit open - Indicator led - Brake fluid level switch - Park brake switch - Red brake warning indicator driver circuit open - Brake fluid level switch ground circuit open - Instrument cluster - Powertrain control module Front Fog Lamp Indicator Inoperative Test 1 - 2 SYMPTOM FRONT FOG LAMP INDICATOR INOPERATIVE POSSIBLE CAUSES - Front fog lamp indicator circuit open - Indicator led - Instrument cluster Fuel Gauge Inaccurate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 224 Test 1 - 2 Test 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Fuel level sensor - Intermittent condition - Instrument cluster High Beam Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 225 Test 1 - 2 SYMPTOM HIGH BEAM INDICATOR INOPERATIVE POSSIBLE CAUSES - High beam indicator circuit open - High beam indicator bulb - Instrument cluster Instrument Cluster Dimming Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 226 Test 1 - 3 SYMPTOM INSTRUMENT CLUSTER DIMMING INOPERATIVE POSSIBLE CAUSES - DTC present - Headlamp switch output circuit open - Illumination bulb - Instrument cluster Low Oil Pressure Indicator Always on Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 227 Test 1 - 3 SYMPTOM LOW OIL PRESSURE INDICATOR ALWAYS ON POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit short to ground - Powertrain control module - Instrument cluster Low Oil Pressure Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 228 Test 1 - 3 Test 4 SYMPTOM LOW OIL PRESSURE INDICATOR INOPERATIVE POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit open - Indicator led - Powertrain control module - Instrument cluster One Gauge Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 229 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE POSSIBLE CAUSES - Powertrain control module DTCs - Instrument cluster PRND or Autostick Indicator Display Inaccurate or Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 230 Test 1 - 2 SYMPTOM PRND OR AUTOSTICK INDICATOR DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - DTC present - Intermittent condition - Instrument cluster Rear Fog Lamp Indicator Inoperative - BUX Only Test 1 - 2 SYMPTOM REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY POSSIBLE CAUSES - Rear fog lamp indicator circuit open - Indicator led - Instrument cluster Seat Belt Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 231 Test 1 - 4 Test 5 SYMPTOM SEATBELT INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator led - Seat belt indicator circuit open - Seat belt switch ground open - Seat belt switch - Instrument cluster Temperature Display Inoperative or Wrong (2.0L Only) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 232 Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INOPERATIVE OR WRONG (2.0L ONLY) POSSIBLE CAUSES - DTC present in PCM - Ambient temperat1jre sensor - Compass/temperature mirror VF Display Inoperative Test 1 SYMPTOM VF DISPLAY INOPERATIVE POSSIBLE CAUSES - Instrument cluster Courtesy Lamps Inoperative - All Lamps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 233 Test 1 - 3 SYMPTOM COURTESY LAMPS INOPERATIVE - ALL LAMPS POSSIBLE CAUSES - Fused B+ circuit open - Instrument cluster - courtesy lamp open - Courtesy lamp driver circuit open - Intermittent condition Courtesy Lamps On At All Times Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 234 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 235 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 236 Test 8 - 10 SYMPTOM COURTESY LAMPS ON AT ALL TIMES POSSIBLE CAUSES - Drivers door ajar switch - Drivers door ajar switch sense wire short to ground - Remote keyless entry module - if equipped - Instrument cluster - Instrument cluster - Panel lamps dimmer signal wire short to ground - Multifunction switch - Open door ajar switch - Remote keyless entry module - if equipped - Passenger door ajar/RKE sense wire short to ground - Instrument cluster - Courtesy lamp driver circuit short to ground - Instrument cluster Illuminated Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 237 Test 1 - 2 SYMPTOM ILLUMINATED ENTRY INOPERATIVE POSSIBLE CAUSES - Courtesy lamps operational - Intermittent condition - Illuminated entry not enabled All Door Locks Inoperative Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 238 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 239 Test 8 - 13 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 240 Test 14 - 16 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Decklid release relay output wire short to ground - Fused B(+) circuit open - Fused B(+) wire short to ground - Ground circuit open - Door lock relay output circuit open - Driver door unlock relay output short to door lock relay output - Driver door unlock relay output wire short to ground - Door lock relay output wire short to ground - Door unlock relay output short to door lock relay output - Decklid release solenoid-shorted - Door unlock relay output wire short to ground - Defective fuse #14 - RKE module - B(+) short to ground - RKE module - relays open - RKE module - shorted All Doors Except Driver Fail to Lock and Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 241 Test 1 - 4 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO LOCK AND UNLOCK POSSIBLE CAUSES - RKE module - open door unlock relay output - Door unlock relay output wire open - Door lock relay output wire open - Open motors All Doors Except Driver Fail to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 242 Test 1 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO UNLOCK POSSIBLE CAUSES - Door unlock relay output circuit short to ground - Remote keyless entry module unlock relay Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTOMATIC DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Auto door locks not enabled - Door ajar status - PCM DTC's present - RKE module defective - auto locks inoperable Decklid Solenoid Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 243 Test 1 - 4 SYMPTOM DECKLID SOLENOID INOPERATIVE POSSIBLE CAUSES - Solenoid ground open - Decklid release solenoid open - Decklid release relay output wire open - RKE module - decklid relay open Doors Lockable With Key In Ignition and Driver Door Open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 244 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 245 Test 4 - 10 SYMPTOM DOORS LOCKABLE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Driver door ajar switch - open - Open driver door ajar switch sense to RKE module - Ignition switch open - Key-in ignition switch sense wire open - Open driver door ajar switch sense to cluster - Instrument cluster - key-in ignition open - Instrument cluster defective-driver door ajar open - RKE module defective-open driver door ajar Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 246 Driver Door Fails to Lock and Unlock Test 1 - 3 Test 4 SYMPTOM DRIVER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - RKE module - open driver unlock circuit - Driver door lock motor - open - Driver door lock relay output wire open - Driver door unlock relay output wire open Driver Door Fails to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 247 Test 1 SYMPTOM DRIVER DOOR FAILS TO UNLOCK POSSIBLE CAUSES - Driver door unlock relay output wire short to ground - RKE module defective - driver unlock open One Passenger Door Fails to Lock and Unlock Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 248 Test 4 - 6 SYMPTOM ONE PASSENGER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - Door lock motor open - Door unlock relay output wire open - Door lock relay output wire open - Door unlock relay output wire short to ground - Door unlock relay output short to door lock relay output - Door lock relay output wire short to ground Remote Keyless Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 249 Test 1 - 3 Test 4 - 5 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - Test RKE transmitter Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 250 - RKE transmitter - inoperative - RKE module - RKE module - receiver inoperable Alarm Trips On Its Own Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition All Doors Fail to Lock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 251 Test 1 - 4 Test 5 SYMPTOM ALL DOORS FAIL TO LOCK POSSIBLE CAUSES - Door lock relay output circuit short to ground - Decklid release relay output short to door lock relay output - Decklid release relay output short to driver door unlock relay output - Decklid release relay output short to door unlock relay output - Remote keyless entry module - unlock ground open All Locks Inoperative From A Door Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 252 Test 1 - 3 Test 4 - 6 SYMPTOM ALL LOCKS INOPERATIVE FROM A DOOR LOCK SWITCH POSSIBLE CAUSES - DTC present Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 253 - Door switch ground wire open - Door switch MUX wire short to voltage - Door switch MUX wire open - Door lock switch open - Remote keyless entry module - high voltage - Remote keyless entry module - low voltage Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH DURING ALARM POSSIBLE CAUSES - Dimmer switch low beam output circuit open - Remote keyless entry module Horn Fails to Sound When Alarm Is Tripped Test 1 SYMPTOM HORN FAILS TO SOUND DURING ALARM POSSIBLE CAUSES - Horn relay control circuit open - Remote keyless entry module Intrusion Sensor Cannot Be Disabled Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 254 Test 1 SYMPTOM INTRUSION SENSOR CANNOT BE DISABLED (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Intrusion Sensor Fails to Trip VTSS Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 255 Test 4 - 6 SYMPTOM INTRUSION SENSOR FAILS TO TRIP VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Open fused B(+) circuit - Open ground circuit - Intrusion sensor signal circuit open - Intrusion sensor signal circuit shorted to ground - Intrusion sensor - Remote keyless entry module Intrusion Sensor Repeatedly Triggers VTSS Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 256 SYMPTOM INTRUSION SENSOR REPEATEDLY TRIGGERS VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Open Driver Door Fails to Trip Alarm Test 1 - 3 SYMPTOM OPEN DRIVER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Remote keyless entry module Open Passenger Door Fails to Trip Alarm Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 257 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 258 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 259 Test 7 - 8 SYMPTOM OPEN PASSENGER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Left rear door ajar switch ground circuit open - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Right rear door ajar switch ground circuit open - Passenger door ajar/RKE sense circuit open - Left rear door ajar switch - Passenger door ajar/RKE sense circuit open - Right rear door ajar switch - Passenger door ajar/RKE circuit open - Passenger door ajar/RKE sense circuit open - Remote keyless entry module - RKE module - passenger door ajar sense Park Lamps Fail to Flash During Alarm Test 1 SYMPTOM PARK LAMPS FAIL TO FLASH DURING ALARM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 260 POSSIBLE CAUSES - Park lamp switch output circuit open - Remote keyless entry module VTSS Fails to Arm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Fails to Arm From Passenger Door Cylinder Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 261 Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM PASSENGER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Passenger door switch MUX circuit open - Passenger cylinder lock switch faulty VTSS Fails to Arm/Disarm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM/DISARM FROM DRIVER DOOR CYLINDER LOCK SWITCH Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 262 TEST NOTE This symptom is diagnosed using the test VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY). POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Indicator Fails to Flash Test 1 - 3 SYMPTOM VTSS INDICATOR FAILS TO FLASH POSSIBLE CAUSES - Remote keyless entry module - Instrument cluster - VTSS indicator driver circuit open - VTSS led open VTSS Indicator Stays On Steady During Arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 263 Test 1 - 5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 264 Test 6 - 8 SYMPTOM VTSS INDICATOR STAYS ON STEADY DURING ARMING POSSIBLE CAUSES - Decklid security switch sense circuit open (if equipped) - Decklid security switch ground circuit open (if equipped) - Decklid security switch (if equipped) - Hood ajar switch sense circuit shorted to ground (if equipped) - Hood ajar switch (if equipped) - RKE module - VTSS indicator - RKE module - hood ajar (if equipped) - RKE module - decklid security (if equipped) VTSS Siren Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 265 Test 4 - 6 SYMPTOM VTSS SIREN INOPERATIVE (EXPORT ONLY) POSSIBLE CAUSES - Siren functional test - Open fused B(+) circuit - Open ground circuit - Faulty siren - Siren control circuit open - Siren control circuit shorted to ground - Remote keyless entry module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 266 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Road Testing ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. during the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 267 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: Erase the stored codes - Place the ignition in the Run position - Wiggle the wire harness and connectors - Rotate the steering wheel from stop to stop - Recheck for active codes periodically as you work through the system. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 268 The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Glossary of Terms ABS Antilock Brake System ACM Airbag Control Module AECM Airbag Electronic Control Module (ACM) ASDM Airbag System Diagnostic Module (ACM) BUX Built-Up Export CAB Controller Antilock Brake CTM Compass/Temperature Mirror DAB Driver Airbag DLC Data Link Connector DTC Diagnostic Trouble Code EMIC Electro/Mechanical Instrument Cluster LSIACM Left SIACM NGC Next Generation Controller PAB Passenger Airbag PCI Programmable Communication Interface (Vehicle Communication Bus) PCM Powertrain Control Module PDC Power Distribution Center PWM Pulse Width Modulated RKE Remote Keyless Entry RSIACM Right SIACM SAB Side Airbag SIACM Side Impact Airbag Control Module SKIM Sentry Key Immobilizer Module SKIS Sentry Key Immobilizer System SQUIB Also Called Initiator (Located In Rear Of Airbag Module) TCM Transmission Control Module VFD Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 269 Body Control Module: Scan Tool Testing and Procedures DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 270 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. DRB III Safety Information DRB III (R) SAFETY INFORMATION WARNING: EXCEEDING THE LIMITS OF THE DRB III (R) MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLE FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS. Follow the vehicle manufacture's service specifications at all times. Do not use the DRB Ill(R) if it has been damaged. Do not use the test leads if the insulation is damaged or if metal is exposed. To avoid electrical shock, do not touch the test leads, tips, or other circuit being tested. Choose the proper range and function for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Do not exceed the limits shown in the table. Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. The circuit being tested must be protected by a 10A fuse or circuit breaker. Use the low current shunt to measure circuits up to 10A. Use the higher current clamp to measure circuits exceeding 10A. When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. When measuring current, connect the meter in series with the load. Disconnect the live test lead before disconnecting the common test lead. When using the meter function, keep the DRB III (R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 271 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read out box) Jumper Wires Ohmmeter Voltmeter Test Light 8310 Airbag Load Tool 8443 SRS Airbag System Load Tool Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 280 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 281 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 282 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 283 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 284 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 285 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 286 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 287 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 293 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 294 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 295 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 300 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 301 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 302 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 303 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 304 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 305 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 306 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 307 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 313 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 314 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 315 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 316 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws 4 Nm 35 In. Lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 319 Powertrain Control Module: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 320 Fig. 12 Engine (Right Front) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 321 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 322 Fig. 43 Engine (Right Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views Powertrain Control Module: Connector Views Powertrain Control Module C1 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 325 Powertrain Control Module C2 (2.0L NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 326 Powertrain Control Module C3 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 327 Powertrain Control Module C4 (EATX NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read Powertrain Control Module: Description and Operation Important - Please Read IMPORTANT (NGC) New for the 2003 PL is a combined Powertrain Control Module and Transmission Control Module in a single control module. This new module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 330 Powertrain Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Fig.5 PCM 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, transmission, and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Ambient Air temperature Sensor - ASD Sense - Baro/Tip (Turbo) - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 331 - Clutch Upstop Switch (1.6L) - Clutch Interlock - Crankshaft Position Sensor - Cruise Control Switch - Electronic Throttle Control (1.6L only) - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - J1850 - Knock Sensor (1.6, 2.0, 2.4L only) - Natural Vacuum Leak Detection (NVLD) - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Pedal Position Sensor (1.6L has 2 sensors) - Power Steering Pressure Switch - SCI Receive - Speed Control Switches - Throttle Position Sensor (1.6L has 2 TPS Sensors) - Transmission Control Relay (Switched B+) - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transmission Pressure Switches (L/R, 2/4, OD) - Transmission Range Sensor (TRS) - Transmission Oil Temperature Sensor (Integral to TRS) - Vehicle Speed Sensor (MTX-equipped models). NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp (Bus Message) - SCI Transmit - Proportional Purge Solenoid - EGR Solenoid - Electronic Throttle Control (1.6L only) - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor (2.0/2.4L) - Ignition Coils - J1850 - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Oxygen Sensors Heater Controls - Radiator Fan Relays - Speed Control Solenoids (2.0/2.4L) - Transmission Control Relay - Transmission Solenoids (LR/CC, 2/4, OD, and UD) - Transmission PRNDL Position (to Cluster) - Transmission Torque Reduction Request (Internal to PCM) - Transmission Temperature (Internal to PCM and a Bus Message) - Vehicle Speed (Manual Transmission) - 2 Electronic Throttle Control Outputs (1.6L) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 332 The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. Air conditioning sense - Battery voltage - Battery temperature - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The Auto Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off from the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Powertrain Control Module Connectors The PCM is an engine and transmission controller module all in one, if the vehicle is equipped with an automatic transmission. The PCM uses four wiring harness connectors to receive and send engine and transmission data. To ease assembly, the mating wiring harness connector is color-coded. Each module connector cavity has its own unique color identification stripe located on the outside of each connector cavity. The PCM module utilizes four wiring harness connectors as described: - Connector Cavity A is for Power & Ground (Black) - Connector Cavity B is for Engine Side (Orange) - Connector Cavity C is for Headlamp & Dash (White) - Connector Cavity D is for Transmission (Green) If equipped. NOTE: Connector Cavities A, B, C, And D must be connected prior to battery connection and ignition key on to avoid setting erroneous controller fault codes. It is also recommended that cavity A connector is made prior to any other connectors. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) An important function of the PCM is to monitor Transmission Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 333 Fig.6 Example Of CVI Calculation By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRBIII Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: TRANSMISSION SHIFT SCHEDULES The PCM is programmed to allow it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 334 - Software calibration level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Electronic Throttle Control (1.6L) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Pedal Position Sensor (1.6L) - Throttle position sensor - Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 335 Powertrain Control Module: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING PCM POWER AND GROUND CIRCUITS POSSIBLE CAUSES - (A14) PCM fused B+ circuit - (A41) PCM fused ignition switch output circuit - (Z12) PCM ground circuits Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 338 Powertrain Control Module: Service and Repair Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 339 Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 340 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL Fig.4 Battery Cable 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 341 Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 342 Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 343 Powertrain Control Module: Service and Repair PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 344 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 345 Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 346 Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 347 Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Removal and Installation REMOVAL Fig.4 Battery Cable Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 348 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 349 Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 350 When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Obtaining Diagnostic Trouble Codes BULB CHECK Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 351 Key on: Bulb illuminated until vehicle starts, as long as all once per trip (readiness) monitors completed. If monitors have not been completed, then: Key on: bulb check for about 5 to 8 seconds, lamp then flashes if once per trip (readiness) monitors have not been completed until vehicle is started, then MIL is extinguished. OBTAINING DTC'S USING DRB SCAN TOOL 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 instrument panel; near the steering column. 2. Turn the ignition switch on and access the "Read Fault" screen. 3. Record all the DTC's and "freeze frame" information shown on the DRB scan tool. 4. To erase DTC's, use the "Erase Trouble Code" data screen on the DRB scan tool. Do not erase any DTC's until problems have been investigated and repairs have been performed. Pinion Factor Setting NOTE: This procedure must be performed if the PCM/TCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM/TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain/ Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRBIII scan tool. 1. Plug the DRBIII scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRBIII scan tool screen. Quick Learn Procedure The quick learn procedure requires the use of the DRBIII scan tool. This program allows the PCM/ TCM to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain/Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBIII indicates the procedure is complete - The calculated oil temperature must be above 60° and below 200° 1. Plug the DRBIII scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRBIII to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 355 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 360 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 361 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump 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 the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 365 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Variable Induction Control Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Variable Induction Control Relay > Component Information > Locations > Page 369 Manifold Tuning Valve Relay (RT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 375 Air Bag Control Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 376 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 377 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 378 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 379 Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 380 Fig. 56 Body (Right) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 381 Air Bag Control Module: Diagrams Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 382 Air Bag Control Module: Service Precautions WARNING: - THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. - DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 383 Air Bag Control Module: Description and Operation Airbag Control Module AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, safing sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn ON the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp ON for 6-8 seconds. If the lamp turns OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 384 Fig.23 Side Impact Airbag Control Module (SIACM) SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) Vehicles equipped with side impact airbags use two side impact airbag control modules. One is located on each side of the vehicle within the body B-pillar. Each Side Impact Airbag Control Module (SIACM) serves as the impact sensor for its seat mounted airbag. The right side SIACM controls the right seat airbag. The left side SIACM controls the left seat air- bag. Each SIACM contains two accelerometers, both accelerometers must agree in order to deploy the side airbag. In the event of a side impact, the appropriate SIACM will send a electronic signal to its airbag, deploying the airbag. The SIACM communicates with the Airbag Control Module (ACM) via the PCI bus circuit. The SIACM perform self-diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem, the SIACM will set both active and stored Diagnostic Trouble Codes (DTC's). If a DTC is active, the SIACM will request that the airbag warning lamp be turned ON. The results of the system test are transmitted on the PCI bus to the ACM once each second or on a change in lamp state (ON/OFF). If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set, the ACM sends a PCI bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp to be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. The SIACM's are not serviceable and must be replaced even if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 385 Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module Air Bag Control Module: Service and Repair Airbag Control Module REMOVAL Fig.1 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove center console. Refer to Body Interior, Floor Console, Removal. Fig.4 Airbag Control Module (ACM) Remove/Install 3. Remove module mounting nuts and remove module. 4. Disconnect ACM 23-way connector. 5. Remove ACM from vehicle. INSTALLATION 1. Connect ACM connector and ensure that the connector and all locking tabs are engaged. CAUTION: USE SUPPLIED NUTS ONLY. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 9.6 to 14 Nm (85 to 125 in. lbs.) torque. 3. Install center console assembly Refer to Body, Interior, Floor Console Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 388 TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 389 Air Bag Control Module: Service and Repair Side Impact Airbag Control Module REMOVAL The removal and installation of the driver side and passenger side modules is identical. The orientation of the modules is the only difference (which way they are tilted). WARNING: THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. 1. Open hood. Fig.18 Battery Negative Cable Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Remove the lower seat trim. Locate the connector for the seat airbag which is under the seat on the outboard side, attached to the seat frame. Disconnect the harness side of the connector. This is to engage the shorting Clips to disable the side impact airbag system. 4. Remove the lower B-pillar trim from the appropriate side of the vehicle. Refer to Body, Interior, B-Pillar Trim, Removal. 5. Remove the seat belt retractor. Refer to Electrical, Restraints, Front Seat Belt Retractor, Removal. WARNING: DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 390 Fig.23 Side Impact Airbag Control Module (SIACM) 6. Remove the SIACM retaining nuts and ground eyelet. 7. Pull SIACM out of B-pillar. Fig.24 SIACM Connector 8. Disconnect the SIACM electrical connector. 9. Remove the SIACM from the vehicle. INSTALLATION The installation of the driver side and passenger side modules is identical. The orientation of the modules is the only difference (which way they are tilted). WARNING: THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. 1. Connect the SIACM electrical connector. 2. Position the SIACM in the B-pillar and install the retaining nuts. Torque the nuts to 41 Nm (360 in. lbs.). NOTE: Place the ground eyelet over the TOP REAR (towards the rear of the vehicle) weld stud when reattaching the SIACM. This location prevents the eyelet from spinning during tightening. 3. Install the seat belt retractor. Refer to Electrical, Restraints, Front Seat Belt Retractor, Installation. 4. Install the lower B-pillar trim. Refer to Body Interior, B-Pillar Trim, Installation. 5. Connect the harness side of the connector. Install the lower seat trim. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. 6. Close hood. 7. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 395 Starter Relay: Diagrams Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 396 Starter Motor Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 397 Starter Relay: Description and Operation The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter solenoid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 398 Starter Relay: Service and Repair REMOVAL The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 409 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 410 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 411 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 417 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 418 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 419 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 420 Control Module: Locations Fig.11 TCM Location The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 421 Control Module: Description and Operation Fig.11 TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). It mounts on a bracket that is fastened to the rail. The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: -Battery (B+) voltage -Ignition "ON" voltage -Transmission Control Relay (Switched B+) -Throttle Position Sensor -Crankshaft Position Sensor (CKP) -Transmission Range Sensor (TRS) -Pressure Switches (L/R, 2/4, OD) -Transmission Temperature Sensor (Integral to TRS) -Input Shaft Speed Sensor -Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) - Torque Reduction Request (to PCM) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 422 An example of a TCM indirect output is: Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.12 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 12). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 423 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 424 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation Control Module: Service and Repair Removal and Installation REMOVAL NOTE: If the Transmission Control Module (TCM) is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE STANDARD PROCEDURE) 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Partially remove right front wheel splash shield. Fig.13 TCM 60-Way Connector 4. Disconnect TCM 60-way connector (Fig. 13). Fig.14 TCM/Bracket Assembly 5. Remove three (3) TCM bracket-to-rail screws and remove TCM/bracket assembly from vehicle (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 427 Fig.15 TCM Bracket 6. Remove four (4) bracket-to-TCM screws and remove bracket (Fig. 15). INSTALLATION 1. Install TCM to mounting bracket and torque four (4) screws to 12 Nm (105 in. lbs.) (Fig. 15). 2. Install TCM/bracket assembly to rail (Fig. 14). Install and torque three (3) bracket-to-rail screws to 12 Nm (105 in. lbs.). 3. Install TCM 60-way connector and torque to 4 Nm (35 in. lbs.) (Fig. 13). 4. Install and secure right front wheel splash shield. 5. Lower vehicle. 6. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 428 Control Module: Service and Repair Pinion Factor Setting STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRB III scan tool. 1. Plug the DRB III scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRB III scan tool screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 429 Control Module: Service and Repair Quick Learn Procedure STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB III scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° 1. Plug the DRB III scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRB III to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 433 Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 434 Transmission Control System Relay: Diagrams Automatic Shut Down Relay Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 435 Transmission Control System Relay: Description and Operation 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 303) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair Wiper Control Module: Service and Repair REMOVAL Fig.13 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove wiper arms. Refer to Electrical, Wipers/Washers, Wiper Arm, Removal. 3. Remove the left side cowl cover. Refer to Body Exterior, Cowl Cover, Removal. 4. Disconnect the motor posi-lock harness connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Page 440 Fig.14 Wiper Module Remove/Install 5. Remove the wiper module mounting screws and remove the module from vehicle. INSTALLATION 1. Install the windshield wiper module into the vehicle. 2. Install the mounting screws and tighten to 7 - 9 Nm (60 - 80 in. lbs.) torque. 3. Connect the motor posi-lock harness connector. 4. Install the left side cowl cover. Refer to Body, Exterior, Cowl Cover, Installation. 5. Install the wiper arms. Refer to Electrical, Wipers/Washers, Wiper Arm, Installation. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 446 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH (EXPORT) REMOVAL 1. Open hood. Fig.1 Battery Negative Cable - Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Disconnect wire harness connector from hood ajar switch. Fig.2 Hood Ajar Switch Location 4. Firmly press tangs on the bottom side of the switch together and push up through bracket. 5. Remove switch from vehicle. INSTALLATION 1. Firmly press hood ajar switch through bracket. 2. Connect wire harness connector to hood ajar switch. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 451 Lock Cylinder Switch: Connector Locations Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 452 Fig. 45 Door (Passenger) - RHD Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 453 Lock Cylinder Switch: Diagrams Right Cylinder Lock Switch (Export) Left Cylinder Lock Switch (Premium) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 454 Lock Cylinder Switch: Service and Repair DOOR CYLINDER LOCK SWITCH REMOVAL 1. Remove the door trim panel. Refer to Body, Door - Front, Trim Panel, Removal. 2. Remove the illuminated entry switch wiring clip and disconnect connector. 3. Remove door cylinder lock switch from door handle. INSTALLATION 1. Install the door cylinder lock switch from door handle. 2. Install the illuminated entry switch wiring clip and disconnect connector. 3. Install the door trim panel. Refer to Body, Door - Front, Trim Panel, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Locations Road Temperature Sensor: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Locations > Page 458 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 463 Fig. 48 Decklid - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Page 464 Decklid Security Switch (Knock Out) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Page 465 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair DECKLID SECURITY SWITCH REMOVAL The Vehicle Theft Security System (VTSS) Deck Lid Security Switch is mounted to the back of the deck lid lock cylinder. 1. Open deck lid. 2. Disconnect wire connector to switch. 3. Remove the spring clip retainer. 4. Pull switch off of deck lid lock cylinder and remove from vehicle. INSTALLATION 1. Push switch onto the deck lid lock cylinder. 2. Install the spring clip retainer. 3. Connect the wire connector to switch. 4. Close the deck lid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions Intrusion Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 470 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 471 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 472 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 473 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 474 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 475 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 476 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 477 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 478 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 479 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 480 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 481 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 482 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 484 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 489 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 490 Intrusion Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 491 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 492 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Domelamp / Intrusion Sensor (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 495 Intrusion Sensor: Electrical Diagrams PLEASE NOTE: Some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-39-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 496 8w-39-3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 497 8w-39-4 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 498 8w-39-5 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 499 8w-39-6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 500 8w-39-7 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 501 8w-39-8 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 502 8w-39-9 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 503 8w-39-10 (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 504 8w-39-11 (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 505 8w-39-12 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 506 8w-39-13 (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 507 8w-39-14 (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 508 8w-39-15 (Export) NOTE: Other diagrams referred to by number (8W-70-2, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 509 Intrusion Sensor: Description and Operation ULTRASONIC INTRUSION SENSOR Fig.3 VTSS Intrusion Sensor Some vehicles equipped with the premium Vehicle Theft Security System (VTSS) use a ultrasonic intrusion sensor. This intrusion sensor is integrated into the dome lamp and detects any movement in the cabin when the VTSS system and the intrusion sensor are armed The sensor cannot be serviced separately and if found to be faulty the entire dome lamp assembly must be replaced In the event the intrusion sensor detects movement inside the vehicle's interior (with system armed), the ARKEM module will sound the siren. DISARMING THE INTRUSION SENSOR - Press the "LOCK" button on Remote Keyless Entry transmitter THREE times within five (5) seconds This operation must be performed during the first 16 seconds of VTSS system arming - Rotating the drivers door key cylinder THREE times within five (5) seconds This operation must be performed during the first 16 seconds of VTSS system arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 510 Intrusion Sensor: Service and Repair ULTRASONIC INTRUSION SENSOR REMOVAL 1. Disconnect and isolate the negative battery cable Fig.4 Dome Lamp Unit With Intrusion Sensor Removal 2. Grasp the dome lamp unit with intrusion sensor and rotate counterclockwise. 3. Pull straight down on dome lamp unit with intrusion sensor. 4. Disconnect electrical connector. 5. Remove the dome lamp unit with intrusion sensor from the vehicle INSTALLATION 1. Connect electrical connector Fig.5 Dome Lamp Unit With Intrusion Sensor Orientation To Headliner Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 511 2. Orient the dome lamp unit with intrusion sensor in a way that the tabs align with the slots in the headliner. 3. Push the dome lamp unit with intrusion sensor straight up. 4. Rotate the dome lamp unit with intrusion sensor clockwise. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 516 Right Cylinder Lock Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 521 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH (EXPORT) REMOVAL 1. Open hood. Fig.1 Battery Negative Cable - Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Disconnect wire harness connector from hood ajar switch. Fig.2 Hood Ajar Switch Location 4. Firmly press tangs on the bottom side of the switch together and push up through bracket. 5. Remove switch from vehicle. INSTALLATION 1. Firmly press hood ajar switch through bracket. 2. Connect wire harness connector to hood ajar switch. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Door (Driver) - LHD Door (Passenger) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 525 Door (Passenger) - RHD Fig. 61 Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 526 Fig. 62 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 527 Power Door Lock Switch: Diagrams Left Door Lock Switch Passenger Door Lock Motor/Ajar Switch Right Door Lock Switch Right Rear Door Lock Motor/Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 528 Power Door Lock Switch: Testing and Inspection 1. Remove the switch from its mounting location, and disconnect from vehicle wiring harness. (Refer to POWER LOCKS/POWER LOCK SWITCH - REMOVAL). Door Lock Switch Resistance 2. Using an ohmmeter, refer to the DOOR LOCK SWITCH RESISTANCE table to determine if switch resistance is correct in the Lock and Unlock switch positions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 529 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. RKE Module Location 3. Remove the two screws holding the RKE module to the instrument panel assembly. 4. Slide locking tab of the wiring connector sideways to unlock tab, and remove connector from RKE module. 5. Remove RKE module from vehicle. NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Additionally, all transmitters must be reprogrammed to the new RKE module. 1. Install the RKE module into the vehicle. 2. Connect the RKE wiring connector. 3. Install the two screws holding the RKE module to the instrument panel assembly. 4. Install the instrument panel top cover. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Door (Driver) - LHD Fig. 61 Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 533 Power Mirror Switch: Diagrams Power Mirror Switch (LHD) Power Mirror Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test Power Mirror Switch: Testing and Inspection Power Foldaway Mirror Switch Test The following test is designed to be used only on vehicles equipped with power fold-away side view mirrors. 1. Remove power mirror switch from mounting position (Refer to POWER MIRRORS/POWER FOLDAWAY MIRROR SWITCH - REMOVAL). Fig.2 Power Fold-Away Mirror Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the tables below. NOTE: When testing using the chart below be certain to read the chart correctly. Example - When testing left mirror "DOWN", pins 1, 9,10 will show continuity to each other, and pins 3, 4, 5 will show continuity to each other. 3. If test results are not obtained as shown in the tables below, replace the switch. Extended Mirror Switch Circuit Test Extended Mirror Switch Circuit Test NOTE: MIRROR POSITION SWITCH MUST BE IN THE "UNFOLD" POSITION TO USE CHART. Retracted Mirror Switch Circuit Test Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 536 Retracted Mirror Switch Circuit Test NOTE: MIRROR POSITION SWITCH MUST BE IN THE "FOLD" POSITION TO USE CHART. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 537 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove power mirror switch 2. Disconnect wiring harness connector from switch. Power Mirror Switch Table ( Part 1 Of 2 ) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 538 Power Mirror Switch Table ( Part 2 Of 2 ) 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 539 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on window switch bezel and remove from door trim panel. 3. Disconnect wire connector from switch. 4. Remove two switch retaining screws. INSTALLATION 1. Install the retaining screws. 2. Reconnect the wire connector to the switch. 3. Insert switch into door trim panel 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Description and Operation Sunroof / Moonroof Limit Switch: Description and Operation LIMIT SWITCH DESCRIPTION The Sunroof Limit Switch is located in the drive motor assembly housing and is not serviceable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Sunroof Switch Sunroof Vent Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 552 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 553 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 554 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 555 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 556 Fig. 35 Decklid - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 557 Decklid Release Switch (Power Release) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 558 Trunk / Liftgate Switch: Service and Repair DECKLID RELEASE SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry out on the deck lid release switch and pull out of instrument panel. 4. Disconnect the wiring connector. 5. Remove switch from vehicle. INSTALLATION 1. Connect the wiring connector. 2. Align switch in hole and firmly snap into place. 3. Close the glove box door. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 563 Fig. 37 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 564 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 565 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 566 Brake Fluid Level Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 567 Brake Fluid Level Sensor/Switch: Service Precautions CAUTION: An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system. The entire brake hydraulic system should be checked for evidence of a leak. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 568 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch is located in the left side of the brake fluid reservoir on the master cylinder. It is clipped into the reservoir. It can be removed from the reservoir and replaced if necessary. OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder reservoir has dropped below an acceptable level. As the fluid drops below the designed level, the fluid level switch closes and grounds the red BRAKE warning indicator circuit. This turns on the red BRAKE warning indicator. At this time, the master cylinder brake fluid reservoir must be checked and filled to the full mark with DOT 3 brake fluid. Check the entire brake hydraulic system for evidence of a leak. CAUTION: An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system. The entire brake hydraulic system should be checked for evidence of a leak. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 569 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir. 2. Push together the retaining tabs holding the brake fluid level switch in place in the brake fluid reservoir. 3. Pull the brake fluid level switch out the other side of the reservoir. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Align the brake fluid level switch with its mounting hole on the left side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs are expanded on the other side of the reservoir, locking it in place. 2. Connect the brake fluid level switch wiring connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 573 Fig. 27 Center Console - LHD Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications TORQUE SPECIFICATIONS ABS Wheel Speed Sensor Mounting Screw ...................................................................................................................................... 12 Nm (105 in. lbs.) WHEEL SPEED SENSOR AIR GAP Front Sensor ........................................................................................................................................ ......................... 0.28 - 1.42 mm (0.011 - 0.056 in.) Rear Sensor ........................................................ .......................................................................................................... 0.45 - 1.12 mm (0.018 - 0.044 in.) TONE WHEEL RUNOUT Front .................................................................................................................................................... ................................................................. 0.009 in. Rear .................................................................... .................................................................................................................................................. 0.009 in. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations TONE WHEELS FRONT REAR WHEEL SPEED SENSORS FRONT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 579 REAR Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 580 Wheel Speed Sensor: Connector Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 581 Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 582 Fig. 5 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 583 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 584 Fig. 37 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 585 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 586 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 587 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 588 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Right Rear Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel Wheel Speed Sensor: Description and Operation Tone Wheel TONE WHEEL DESCRIPTION The tone wheel is used in conjunction with the wheel speed sensors. OPERATION The tone wheel is used in conjunction with the wheel speed sensors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 591 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor Front FRONT WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A wheel speed sensor is used at each wheel. The gear (tooth) type tone wheel serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one tone wheel. The front wheel speed sensors are attached to bosses in the steering knuckle. The tone wheel is an integral part of the outboard constant velocity joint located in the front axle shaft. WSS air gaps are not adjustable. The initial factory WSS air gap specification can be found in SPECIFICATIONS. Each WSS is serviced individually. The tone wheels are serviced as Dart of the drive shaft. OPERATION The CAB sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the CAB. The Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 592 relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the CAB, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the CAB. When a valley of the tone wheel is aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the CAB. As the tone wheel rotates, the tooth shifts the magnetic field and the IC enables a second 7 mA current source. The CAB senses a voltage signal of approximately 1.6 volts and 14 mA. The CAB measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABS CAB as the wheel speed. Rear REAR WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A wheel speed sensor is used at each wheel. The gear (tooth) type tone wheel serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one tone wheel. The rear wheel speed sensors are mounted through the disc brake adapter. The rear tone wheels are mounted to and rotate with the hub and bearing assemblies. The WSS air gaps are not adjustable. The initial factory WSS air gap specification can be found in SPECIFICATIONS. Each WSS is serviced Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 593 individually. The tone wheels are serviced as an assembly with the hub and bearing assemblies. OPERATION The CAB sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the CAB. The relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the CAB, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the CAB. When a valley of the tone wheel is aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the CAB. As the tone wheel rotates, the tooth shifts the magnetic field and the IC enables a second 7 mA current source. The CAB senses a voltage signal of approximately 1.6 volts and 14 mA. The CAB measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABS CAB as the wheel speed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 594 Wheel Speed Sensor: Testing and Inspection TONE WHEEL INSPECTION Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes: missing, chipped, or broken teeth - contact with the wheel speed sensor - wheel speed sensor to tone wheel alignment - wheel speed sensor to tone wheel clearance - excessive tone wheel runout - tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement, the rear hub and bearing must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive tone wheel runout can cause erratic wheel speed sensor signals. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replace the front driveshaft or rear hub and bearing as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Raise the vehicle. 2. Disconnect the wheel speed sensor cable connector from the wiring harness on the inside of the frame rail above the front suspension crossmember. The connector has a locking tab which that must be pulled back before the connector release tang can be depressed, releasing the connection. 3. If the sensor being removed is a left front, unclip the speed sensor cable from the brake tube on the inside of and under the frame rail. 4. Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 597 5. Remove the bolt mounting the wheel speed sensor head to the steering knuckle. CAUTION: When removing a wheel speed sensor from the knuckle, do not use pliers on the sensor head. This may damage the sensor head. If the sensor has seized, use a hammer and a punch to tap the edge of the sensor head ear, rocking the sensor side-to-side until free. 6. Carefully, remove the sensor head from the steering knuckle. 7. Remove the screw securing the wheel speed sensor to the rear of the strut. Remove the wheel speed sensor. INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Attach the wheel speed sensor to the strut using the its mounting screw. 2. Install the wheel speed sensor head in the steering knuckle. Install the mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. From the sensor bracket on the strut, loop the sensor cable upward, then downward at the outside of the frame rail. Install the speed sensor cable grommet onto the retaining bracket attached to the brake hose on the outside of the frame rail. 4. Loop the wheel speed sensor cable around the bottom of the frame rail and connect it to the wiring harness connector on the inside of the frame rail. Remember to push in the locking tab on the connector. 5. If the sensor being installed is the left front, clip the speed sensor cable to the brake tube on the inside of and under the frame rail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 598 6. Lower the vehicle. 7. Road test vehicle to ensure proper operation of the base brakes and ABS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 599 Wheel Speed Sensor: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Raise the vehicle. 2. Disconnect the wheel speed sensor cable connector from the vehicle wiring harness. Remove the clip attaching wheel speed sensor cable connector to the vehicle's body. 3. Remove the wheel 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. 4. Remove the bolt attaching the wheel speed sensor cable routing bracket to rear strut. CAUTION: When removing a wheel speed sensor from the rear disc brake adapter, do not use pliers on the sensor head. This may damage the sensor head. If the sensor has seized, use a hammer and a punch to tap the edge of the sensor head ear, rocking the sensor side-to-side until free. 5. Remove the bolt attaching the wheel speed sensor to the rear disc brake adapter, then carefully remove the sensor head from the rear disc brake Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 600 adapter and vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head into the disc brake adapter. 2. Install the wheel speed sensor mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. Install the wheel speed sensor cable routing bracket on the rear strut. 4. Install wheel speed sensor cable into the routing clips on the rear brake hose and brake tube. 5. Connect the wheel speed sensor cable connector into vehicle wiring harness. Install the clip attaching the wheel speed sensor cable connector to vehicle's body. 6. Lower the vehicle. 7. Road test the vehicle to ensure proper operation of the base brakes and ABS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Application and ID Coolant Temperature Sensor / Switch HVAC: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Climate Controls .................................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 609 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 610 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 611 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 612 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 623 Cruise Control Switch: Service Precautions WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 624 Cruise Control Switch: Description and Operation SPEED CONTROL SWITCHES The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM The switch names are ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, COAST, and CANCEL Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, TAP-DOWN, COAST, and CANCEL Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed The individual switches cannot be repaired If one switch fails, the entire switch module must be replaced Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 625 Cruise Control Switch: Service and Repair SPEED CONTROL SWITCHES The speed control switch is mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS. Fig.7 Speed Control Switch REMOVAL 1. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 2. Remove the negative battery cable. 3. Turn off ignition. 4. Remove air bag, refer to the Restraint systems section. Fig.8 Switch Top Mounting Screw 5. Remove the top mounting screw. 6. Rotate steering wheel so that the switch is in the 6 o'clock position. Remove 2 screws from the back side of the speed control switch. 7. Disconnect the electrical connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 626 Fig.9 Switch Removal 8. Remove switch. INSTALLATION 1. Connect the electrical connector. 2. Install switch and tighten the screws to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch. 3. Install airbag, refer to the Restraint Systems section. 4. Install the negative battery cable. 5. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation OIL PRESSURE SENSOR/ SWITCH DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 120). The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). OPERATION The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig of the switch's "Closed" circuit pressure point. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Page 631 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle. 2. Position oil collecting container under pressure switch location. 3. Disconnect oil pressure switch electrical connector and remove switch (Fig. 121). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 121). 2. Lower vehicle. 3. Start engine and allow to run a minimum of 2 minutes. 4. Shut engine off and check engine oil level. Adjust level as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 635 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Diagrams A/C Cycling Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 643 Ambient Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 644 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the compass/temp module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 degrees C (140 degrees F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 degrees C (140 degrees F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 degrees C (-49 degrees F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 degrees C (-49 degrees F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 645 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: 0 degrees C (32 degrees F) Sensor Resistance = 29.33 - 35.99 Kilohms 10 degrees C (50 degrees F) Sensor Resistance = 17.99 - 21.81 Kilohms 20 degrees C (68 degrees F) Sensor Resistance = 11.37 - 13.61 Kilohms 25 degrees C (77 degrees F) Sensor Resistance = 9.12 - 10.86 Kilohms 30 degrees C (86 degrees F) Sensor Resistance = 7.37 - 8.75 Kilohms 40 degrees C (104 degrees F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 646 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable. 2. Working under the front of the vehicle, remove the necessary components to access the ambient temperature sensor. 3. Disconnect the ambient temperature sensor electrical connector. 4. Remove the ambient temperature sensor retaining screw and remove the sensor from the vehicle. INSTALLATION 1. Connect the ambient temperature sensor electrical connector. 2. Position the ambient temperature sensor and install the retaining screw. 3. Install the removed components. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Coolant Temperature Sensor / Switch HVAC > Component Information > Application and ID Coolant Temperature Sensor / Switch HVAC: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Climate Controls .................................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Fig.22 Evaporator Probe Location - Typical The evaporator probe is located in the A/C housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 653 Evaporator Temperature Sensor / Switch: Description and Operation EVAPORATOR TEMPERATURE SENSOR The evaporator probe can be replaced without having to remove the A/C housing from the vehicle. The evaporator probe is located in the A/C 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 drops below the freeze point. It cycles ON when the evaporator temperature rises above the 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 housing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 654 Evaporator Temperature Sensor / Switch: Testing and Inspection The work area and vehicle must be between 16 °C (60 °F) and 32 °C (90 °F) when testing the switch. Fig.21 Evaporator Probe Harness Connector 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. 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. 7. Close all doors and windows. Place a thermometer in the center discharge vent. 8. If the clutch does not begin to cycle off between 2 - 7 °C (35 - 45 °F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 655 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be removed without removing the A/C Housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Fig.22 Evaporator Probe Location - Typical 2. Remove rubber grommet from evaporator/ blower module. 3. Note which of the three pilot holes the evaporator probe is located in. 4. Pull probe out of evaporator fins. INSTALLATION NOTE: The evaporator probe can be installed without removing the A/C Housing from the vehicle. 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 of approximately 1/8 inch diameter, and make a new hole. Make the hole 1/4 inch above, or below the original hole in the evaporator core. 3. Insert the new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 660 Fig. 2 Engine Compartment (Left) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 661 Fig. 4 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 662 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 663 Fig. 28 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 664 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 665 A/C High Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 666 High Pressure Sensor / Switch: Description and Operation Fig.18 High Pressure Cut Out Switch Location A/C HIGH PRESSURE SWITCH The high pressure cut out switch is located on the rear of the compressor. It turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). The high pressure cut out switch is a factory calibrated unit. The switch cannot be adjusted or repaired and if faulty or damaged, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 667 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 1. Recover refrigerant from A/C system. 2. Disconnect and isolate the battery negative cable. 3. Raise and support the vehicle. High Pressure Cut Out Switch 4. Disconnect the engine wire harness connector from the high pressure cut out switch on the compressor back cover. 5. Using snap ring pliers, remove the internal snap ring that secures the high pressure cut out switch to the switch port in the compressor back cover. 6. Pull the high pressure cut out switch out of the compressor back cover. 7. Install a plug in or tape over the opened switch port on the compressor back cover. 8. Remove the rubber O-ring seal from the high pressure cut out switch and discard. INSTALLATION 1. Clean any foreign matter from the switch mounting bore 2. Install the high pressure cutout switch with a new O-ring. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 3. Remove the tape or plug from the switch port on the compressor back cover. 4. Insert the high pressure cut out switch into the switch port on the compressor back cover. 5. Reconnect the engine wire harness connector to the high pressure cut out switch on the compressor back cover. 6. Lower the vehicle. 7. Reconnect the battery negative cable. 8. Evacuate the refrigerant system. 9. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 671 Fig. 4 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 672 Fig. 27 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 673 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch (LHD) A/C Low Pressure Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 674 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch is a single pole, single throw, pressure actuated switch that is installed in a threaded port into the suction passage of the accumulator. The switch is located on the top of the accumulator in a fitting that contains a Schrader type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with a O-ring to seal the switch plumbing connection. The A/C low pressure switch is a factory calibrated unit. The switch cannot be adjusted or repaired and if faulty or damaged it must be replaced. The A/C low pressure switch monitors the pressure of the refrigerant leaving the accumulator to the compressor. The switch is connected in series electrically with the heater-A/C control blower and mode switches and the high pressure cut out switch between ground and the Powertrain Control Module (PCM). The switch contact open or close the path the ground, signaling the PCM to turn the compressor clutch on and off. This regulates the refrigerant system pressure and controls evaporator temperature. Controlling the evaporator temperature prevents con-densate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The A/C low pressure switch contacts are open when the suction pressure is approximately 152 kPa (22 psi) or lower. The switch contacts will close when the suction pressure rises to approximately 234 - 262 kPa (34 - 38 psi) or above. Lower temperatures, below approximately -1 °C (30 °F), will also cause the switch contacts to open. This is due to the pressure/ temperature relationship of the refrigerant in the system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 675 Low Pressure Sensor / Switch: Testing and Inspection A/C LOW PRESSURE SWITCH Before performing diagnosis of the A/C low pressure switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Also verify that the refrigerant system had the correct refrigerant charge. 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 A/C low pressure 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 A/C low pressure switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 676 Low Pressure Sensor / Switch: Service and Repair A/C LOW PRESSURE SWITCH REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the low pressure cycling switch. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the connector for the A/C low pressure switch from the top connector on the accumulator. 3. Unscrew the A/C low pressure switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator and discard. INSTALLATION NOTE: Replace the O-ring seal before installing the low pressure clutch cycling switch 1. Lubricate the new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the A/C low pressure cycling switch onto the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Reconnect the wiring harness connector to the A/C low pressure switch. 4. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 681 Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 682 Fig. 23 Door (Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 683 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 684 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 685 Fig. 44 Body (Right Rear) - RHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 686 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 687 Door Switch: Diagrams Driver Door Ajar Switch Hood Ajar Switch (Export) Left Rear Door Ajar Switch Passenger Door Ajar Switch Right Rear Door Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 691 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor (track). The resistor track is used to send electrical signals to the instrument cluster for fuel gauge operation and are then transmitted to the engine controller for OBDII emission requirements. For Fuel Gauge Operation: As fuel level increases, the float and arm move up. This increases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This decreases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the instrument cluster, the instrument cluster will transmit the data across the J1850 bus circuits to the PCM. For OBD II Emission Requirements: The voltage signal is sent to the instrument cluster to indicate fuel level. The cluster transmits the fuel level to the PCM where it is used to prevent a false setting of misfire and fuel system monitor trouble codes. This occurs if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 692 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDING UNIT/SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig.4 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 4). Fig.5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge (Fig. 5). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 693 Fig.6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 6). 4. Push level sensor signal and ground terminals out of the connector (Fig. 6). Fig.7 Level Sensor 5. Slide level sensor wires through opening fuel pump module (Fig. 7). 6. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 7). Ensure tab at bottom of sensor locks in place. 4. 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. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 697 Fig. 27 Center Console - LHD Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 702 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 703 Backup Lamp Switch (1.6/2.0L MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 704 Backup Lamp Switch: Service and Repair REMOVAL 1. Lift vehicle on hoist. Fig.1 Back-Up Lamp Switch 2. From bottom side of vehicle, disconnect back-up lamp switch connector. 3. Unscrew switch from transaxle. INSTALLATION 1. Install back-up lamp switch. Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.) torque. CAUTION: Do not overtighten switch. 2. Connect back-up lamp switch connector. 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 709 Brake Light Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 710 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 711 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 712 Brake Lamp Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 713 Brake Light Switch: Service Precautions CAUTION: - The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. - Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 714 Brake Light Switch: Description and Operation BRAKE LAMP SWITCH Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. It has three internal switches controlling various functions of the vehicle. It's main function is to control operation of the vehicle's brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. When the brake pedal is pressed, the plunger on the outside of the brake lamp switch extends outward. This action opens or closes the contacts of the three switches inside the brake lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for terminals 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. A lever on the back of the switch is used to set the switch into the "adjusted" position. A non-adjusted switch will have the lever set to the diagonal position in relation to the switch housing. The plunger can be moved in and out, but the states of the internal switches will not change. CAUTION: Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Fig.5 Adjustment Lever Movement Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 715 Once installed in the vehicle as described in the brake lamp switch installation procedure, the new switch's adjustment lever is rotated to the adjusted position as indicated. This action locks the plunger to the internal switches. Once in this position the switch is permanently adjusted (or locked) and cannot be readjusted or released even if the lever is moved back. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 716 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH DIAGNOSIS NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position, it may have never been adjusted. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. Fig.3 Switch Test - Released Position 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the brake lamp switch in until it stops. Fig.4 Switch Test - Depressed Position 4. With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for any reason, a new switch must be installed and adjusted. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 717 Brake Light Switch: Service and Repair BRAKE LAMP SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Under the instrument panel, remove the brake lamp switch by rotating the switch in a counterclockwise direction approximately 30 degrees and pulling it out of the bracket. 3. Disconnect the wiring harness from the connector on the switch. 4. Discard the brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. This switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 1. Obtain NEW brake lamp switch. The adjustment lever on the new switch should be at a 45° angle from the wiring connector. If the adjustment lever is parallel with the wiring connector, the switch has been preset and must be scrapped. DO NOT ATTEMPT TO RESET (OR READJUST) THE BRAKE LAMP SWITCH. 2. Connect the wiring harness to the connector on the switch. 3. Mount and adjust the NEW brake lamp switch using the following steps: a. Install the switch in its bracket by aligning the index tab on the switch with the notch in the mounting bracket. b. When the switch body is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place. Fig.5 Adjustment Lever Movement c. With the brake pedal in the fully released position, move the adjustment lever on the brake lamp switch from the 45° angled non-adjusted position, clockwise as shown, until it is parallel with the wiring connector. The brake lamp switch is now properly adjusted to the vehicle. 4. Reconnect the battery negative terminal. 5. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 6. Road test the vehicle to ensure proper operation of the brakes (including ABS if equipped) and speed control (if equipped). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 721 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 722 Multi-Function Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 723 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH Turn Signal And Hazard Warning Flasher Diagnosis Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 724 Turn Signal And Hazard Warning Flasher Diagnosis FLASHER DIAGNOSIS Should any function of the multi-function switch fail, the entire switch assembly must be replaced. SWITCH DIAGNOSIS To test the switch: 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shrouds. 3. Disconnect the switch connector. Fig.19 Combination Flasher Connector (A) Fig.20 Multi-Function Switch Connector (B) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 725 Fig.21 Windshield Wiper/Washer Switch Connector (C) Multi-Function Switch Continuity Test Part 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 726 Multi-Function Switch Continuity Test Part 2 Multi-Function Switch Dimmer Control Resistance Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the Multi-Function Switch Continuity Test table for diagnosis. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 727 Combination Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL Fig.22 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove both upper and lower steering column shrouds. Fig.23 Multi-Function Switch Mounting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 728 Fig.24 Multi-Function Switch - Remove/Install 3. Disconnect both posi-lock harness connectors at the rear of the multi-function switch. 4. Remove multi-function switch mounting screws. 5. The combination flasher must be transferred to new multi-function switch if replacing. 6. The windshield wiper/washer switch must be transferred to the new multi-function switch. INSTALLATION 1. The windshield wiper/washer switch must be transferred to the new multi-function switch. 2. The combination flasher must be transferred to new multi-function switch if replacing. 3. Install the multi-function switch mounting screws. Tighten multi-function switch to column retaining screws to 3 Nm (27 in. lbs.) torque. 4. Connect both posi-lock harness connectors at the rear of the multi-function switch. 5. Instal both upper and lower steering column shrouds. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 732 Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 733 Fig. 23 Door (Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 734 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 735 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 736 Fig. 44 Body (Right Rear) - RHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 737 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 738 Door Switch: Diagrams Driver Door Ajar Switch Hood Ajar Switch (Export) Left Rear Door Ajar Switch Passenger Door Ajar Switch Right Rear Door Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fig. 6 Front Fog Lamps - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 742 Fog/Driving Lamp Switch: Diagrams Left Front Fog Lamp Right Front Fog Lamp (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 743 Fog/Driving Lamp Switch: Description and Operation REAR FOG LAMP SWITCH (EXPORT) The Rear Fog Lamp Switch is located on the left stalk of the multi-function switch assembly. The rear fog lamp switch is the primary controller of the rear fog lamps. With the end of the left stalk pulled out, rotate it past the headlamp position to complete the rear fog lamp switch circuit. This illuminates the rear fog lamp or lamps. Headlamps must be ON in order for the rear fog lamp/s to function. Refer to Wiring Diagrams for a complete system schematic. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 744 Fog/Driving Lamp Switch: Service and Repair REAR FOG LAMP SWITCH (EXPORT) REMOVAL AND INSTALLATION Refer to MULTI-FUNCTION SWITCH. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 and isolate the battery negative cable 2. Open glove box door. 3. Pull downward on lamp/switch assembly to disengage tabs from instrument panel. 4. Pull bulb from socket. 5. Disconnect wire connector from lamp and remove glove box lamp/switch. INSTALLATION 1. Push bulb into socket. 2. Place lamp/switch assembly into position. 3. Connect wire connector to the lamp/switch. 4. Push lamp/switch assembly to lock tabs. 5. Check lamp operation, and close glove box door. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 751 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 752 Hazard Warning Switch: Description and Operation Fig.18 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. The visible parts of the multi-function switch are the turn signal control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, the windshield wiper/washer, exterior lighting control stalk that extends through a dedicated opening in the right upper steering column shrouds, the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A connector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Washer Mode - A button on the end of the control stalk of the multi-function switch provides washer system operation when the button is depressed towards the steering column. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Exterior Lighting Control - The internal circuitry and hardware of the multi-function switch provide for activation and deactivation of exterior lighting. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations Fig.12 Headlamp Leveling Switch Location HEADLAMP LEVELING SWITCH The Headlamp Leveling Switch is located on the center instrument panel area in the accessory switch bezel and is the primary controller of the headlamp leveling system. HEADLAMP SWITCH The headlamp switch is integral to the left stalk of the multi-function switch located on the steering column behind the steering wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 757 Headlamp Switch: Connector Locations Fig. 12 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 758 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 759 Headlamp Switch: Description and Operation Fig.13 Headlamp Leveling Switch Location HEADLAMP LEVELING SWITCH - EXPORT The Headlamp Leveling Switch is located on the center instrument panel area in the accessory switch bezel, and is the primary controller of the headlamp leveling system The leveling switch has four settings 0-3, 0 being the lowest, and 3 being the highest headlamp beam vertical setting With the rotation of the headlamp leveling switch control knob, voltage is adjusted at the headlamp leveling switch (rheostat) This signals the headlamp leveling motors (headlamp module mounted) to adjust the vertical headlamp beam pattern accordingly Headlamps must be "ON" in order for the leveling system to function Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 760 Headlamp Switch: Testing and Inspection HEADLAMP LEVELING SWITCH - EXPORT 1. Disconnect and isolate the negative battery cable 2. Remove the headlamp leveling switch. Headlamp Leveling Switch Resistance 3. Using an ohmmeter and the HEADLAMP LEVELING SWITCH RESISTANCE table, check the resistance between switch connector pins 1&2. 4. If the test results are not as indicated in the table below, replace the switch If test results are as indicated below, the switch is OK. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 761 Headlamp Switch: Service and Repair Headlamp Leveling Switch Replacement REMOVAL 1. Rotate the A/C outlet registers to the full down position Grip each outlet at its outboard end and gently over-rotate to release from its pivot point Swing outlet straight out and remove by hand 2. Remove the (4) HVAC control knobs by pulling straight off the switch shaft 3. Remove the (2) screws from the center instrument bezel 4. Remove the center instrument bezel Pull it straight out to unsnap the (4) retaining clips 5. Remove the (2) screws from the accessory switch bank 6. Pull the accessory switch bank out and disconnect the electrical connector from the headlamp leveling switch. Fig.14 Leveling Switch Removal 7. Gently pry the headlamp leveling switch out of its mounting clips. INSTALLATION 1. Snap the headlamp leveling switch into the accessory switch bank. 2. Install the headlamp leveling switch electrical connector. 3. Verify switch operation. 4. Position the accessory switch bank and install the (4) retaining screws. 5. Snap the center instrument bezel in position and install the retaining screws. 6. Install the (4) HVAC control knobs. 7. Install the A/C outlet registers on the center instrument bezel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 765 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 766 Horn Switch: Description and Operation 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 767 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove horn relay from the 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 RESTRAINTS/DRIVER AIRBAG - REMOVAL). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 768 Horn Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Driver Airbag Module. (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). 3. Clip off strap tie holding the horn switch wire to the airbag module. 4. Unclip horn switch wire connector from airbag module. 5. Remove four torx screws from top side of airbag module. 6. Fold airbag module cover down to expose the horn switch. 7. Lift the horn switch off indexing tabs and remove from vehicle. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install horn switch to the indexing tabs on the airbag module. 2. Install screws to the top of airbag module. 3. Reconnect horn switch connector to airbag module. 4. Install the airbag module. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Component Locations Turn Signal Switch: Component Locations The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Component Locations > Page 773 Turn Signal Switch: Connector Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Component Locations > Page 774 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 775 Multi-Function Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 776 Turn Signal Switch: Description and Operation Fig.18 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. The visible parts of the multi-function switch are the turn signal control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, the windshield wiper/washer, exterior lighting control stalk that extends through a dedicated opening in the right upper steering column shrouds, the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A connector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Washer Mode - A button on the end of the control stalk of the multi-function switch provides washer system operation when the button is depressed towards the steering column. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Exterior Lighting Control - The internal circuitry and hardware of the multi-function switch provide for activation and deactivation of exterior lighting. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 783 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 784 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 785 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 786 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 790 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 794 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 795 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 796 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 797 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 802 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 803 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 804 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 805 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 806 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 807 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig.11 Fuel Pump Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 811 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 812 Fuel Level Sensor: Service and Repair Fig.4 Fuel Pump/Level Sensor Electrical Connector Fig.5 Wire Terminal Locking Wedge Fig.6 Removing Wires From Connector Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 813 Fig.7 Level Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 818 Intake Air Temperature (IAT) Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 819 Fig. 8 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 820 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 821 Fig. 48 Left Side Engine - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 822 Inlet Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 823 Intake Air Temperature (IAT) Sensor: Description and Operation Fig.18 Inlet Air Temperature Sensor INLET AIR TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct. The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 824 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the inlet air temperature sensor 3. Remove the air cleaner lid. 4. Disconnect the inlet air tube from the throttle body. 5. Remove inlet air tube from air cleaner lid. INSTALLATION 1. Install inlet air tube to air cleaner lid and tighten clamp. 2. Install inlet air tube to throttle body and tighten clamp. 3. Install air cleaner lid to air cleaner box. 4. Connect the inlet air temperature sensor electrical connector. 5. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 828 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Fig. 15 Engine (Top) (2.0L) - LHD Fig. 48 Engine (Top) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 832 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 833 Manifold Absolute Pressure Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 834 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.23 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezo-resistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key ON is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key ON the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 835 The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 836 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL Fig.24 MAP Sensor The MAP sensor attaches to the intake manifold plenum. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION The MAP sensor attaches to the intake manifold plenum. 1. Insert sensor into intake manifold while making sure not to damage O-ring seal. 2. Tighten mounting screws to 4.5 Nm (40 in. lbs.) torque for plastic manifold. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 840 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 845 Oxygen Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 846 Fig. 13 Engine (Left Rear) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 847 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 848 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 849 Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 850 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 851 Oxygen Sensor: Application and ID - 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 Cylinder #1 on left side. Cylinder #1 on right side. - 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 1/1. - 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 852 Oxygen Sensor: Description and Operation Fig.30 Types Of O2 Sensors Fig.27 Upstream Heated Oxygen Sensor 1/1 O2 SENSOR The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 853 Fig.28 Downstream Heated Oxygen Sensor 1/2 Fig.29 Heated Oxygen Sensor Systems The downstream heated oxygen sensor threads into the system depending on emission package. Federal package the O2S is mounted after the catalytic convertor, LEV package the O2S is mounted mid catalytic convertor, ULEV package is mounted between the catalytic convertor. A single sensor ground is used for all O2 sensors (2 sensors on 4 cyl. vehicles and 4 sensors on 6 cyl. vehicles). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 854 monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM uses pulse width modulation to control the ground side of the heater to regulate the temperature on 4 cyl. upstream O2 heater only. All other 4 cyl. and 6 cyl. O2 heaters do not use pulse width modulation. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (1/2) O2 Sensor Oxygen Sensor: Service and Repair Downstream (1/2) O2 Sensor REMOVAL Fig.32 Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 1. Raise vehicle. 2. Disconnect electrical connector from harness. 3. Disconnect sensor electrical harness from clips along body. Fig.33 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 5. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect sensor electrical harness from clips along body Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (1/2) O2 Sensor > Page 857 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (1/2) O2 Sensor > Page 858 Oxygen Sensor: Service and Repair Upstream (1/1) O2 Sensor REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig.31 Upstream Heated Oxygen Sensor Removal/Installation 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 4. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Plug sensor connector. 3. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 859 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Remover/Installer - C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 864 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 865 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 866 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 867 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 872 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 873 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 874 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 875 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 876 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 882 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 883 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 884 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 885 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 886 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 887 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 888 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Connector Views Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 899 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 900 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 901 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 902 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 903 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 908 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 913 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 914 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 915 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 916 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 917 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 918 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair "For information regarding this component please refer to steering column service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 926 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Fig. 28 Body (Left Front) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 931 Fig. 56 Body (Right) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 932 Seat Belt Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 938 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 939 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 940 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 941 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations > Page 946 Clutch Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations > Page 947 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations > Page 948 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 949 Clutch Interlock/Upstop Switch (MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 950 Clutch Switch: Description and Operation CLUTCH INTERLOCK/UPSTOP SWITCH DESCRIPTION - LHD The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 13). The switch assembly is located in the clutch/brake pedal bracket assembly (Fig. 14), each switch being fastened by four plastic wing tabs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 951 DESCRIPTION - RHD The RHD clutch interlock/upstop switch (Fig. 15) consists of a single, multi-function switch that is activated by hydraulic clutch master cylinder push rod travel. OPERATION - CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch pedal in the up position (not depressed), or under normal conditions with the clutch engaged and the transaxle in gear. WARNING: WHEN THERE IS A LOSS OF CLUTCH SYSTEM HYDRAULIC FLUID, OR THE CLUTCH MASTER CYLINDER PUSHROD IS DISCONNECTED FROM THE PEDAL LEVER, THE ENGINE MAY START WITH THE CLUTCH ENGAGED, CAUSING UNDESIRABLE VEHICLE MOVEMENT IF THE TRANSAXLE IS IN ANY GEAR. The switch is open while the clutch pedal is at rest or in the up position. When the clutch pedal is fully depressed on LHD models, the clutch pedal lever closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. When the clutch pedal is fully depressed on RHD models, the master cylinder push rod closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. The interlock switch is not adjustable. OPERATION - CLUTCH PEDAL UPSTOP SWITCH With the clutch pedal at rest, the clutch pedal upstop switch is closed, allowing speed control operation. When the clutch pedal is depressed, the upstop switch opens and signals the PCM to cancel speed control operation, and enter a modified engine calibration schedule to improve driveability during gear-to-gear shifts. The upstop switch is not adjustable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis Clutch Switch: Testing and Inspection Service Diagnosis SERVICE DIAGNOSIS - CLUTCH INTERLOCK/UPSTOP SWITCH The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 954 The RHD clutch interlock/upstop switch (Fig. 17) consists of a single, multi-function switch that is activated by the hydraulic clutch master cylinder push rod. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 955 Clutch Switch: Testing and Inspection Clutch Interlock Switch / Mechanical-Electrical Tests CLUTCH INTERLOCK SWITCH Mechanical Test 1. With the park brake set and the transaxle IN NEUTRAL, turn the ignition key to the start position. The engine starter should not crank with the clutch pedal at rest (not depressed). If the starter cranks, proceed to the electrical test to determine whether the switch is defective or the circuit is shorted. If the vehicle does not crank, proceed to the next step. 2. With the park brake set and the transaxle IN NEUTRAL, fully depress the clutch pedal and turn the ignition key to the start position. The engine starter should crank. If the starter does not crank, visually inspect the clutch pedal for obstructions (floor mat, etc.). Make sure the clutch pedal lever contacts and fully closes the switch on LHD applications, and for proper installation of the master cylinder push rod/bushing on the pedal pin on RHD applications. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 2 & 3 (Fig. 18) with the interlock switch not depressed (clutch pedal at rest). There should be no continuity between the terminals (open circuit). 5. LHD Models: Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm (0.050 inch) on LHD applications. The ohmmeter should show continuity (0 ohms resistance). RHD Models: Disconnect the push rod from the pedal pin and actuate the push rod by hand to close the switch. The ohmmeter should show continuity (0 ohms). Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked) it MUST be replaced before reinstalling the push rod to the pedal. 6. If ohmmeter readings do not fall within these ranges, the switch assembly, or the pedal bracket assembly, is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 956 Clutch Switch: Testing and Inspection Upstop Switch / Mechanical-Electrical Tests UPSTOP SWITCH Mechanical Test 1. Raise vehicle on hoist. 2. Start engine and operate speed control to maintain speed. 3. Depress clutch pedal at least 33 mm (1.30 inch). Speed control operation should terminate. If speed control does not terminate, the upstop switch is defective or the related wiring is shorted. Proceed to the upstop switch electrical test. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 1 & 2 (Fig. 18) with the upstop switch depressed (clutch pedal at rest). The ohmmeter should show continuity (0 ohms). 5. Depress the clutch pedal at least 33 mm (1.30 inch) check for continuity between terminals 1 & 2. There should be no continuity between the terminals (open circuit). 6. If ohmmeter readings do not fall within these ranges, the switch assembly is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - LHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - LHD 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 19). 3. Disconnect upstop switch and brake lamp switch connectors. 4. Disconnect clutch master cylinder rod from clutch pedal pin. Inspect plastic retainer upon removal. If retainer is damaged, it MUST be replaced. 5. Remove brake booster push rod retaining clip from brake pedal. Disengage rod from pedal (Fig. 20). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 959 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 21). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 21). 8. From under the hood, pull brake master cylinder/booster far enough forward to obtain pedal to bracket stud clearance. 9. Remove the pedal bracket assembly (Fig. 21). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 22) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION - LHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 960 contacting pedals. 1. Install switches into the pedal bracket assembly as shown in (Fig. 22). Route harness as was prior to removal. Secure switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 42 Nm (31 ft. lbs.). 3. Install brake/clutch pedal bracket assembly into position. Install and tighten brake booster mounting nuts to 34 Nm (25 ft. lbs.). Install and tighten pedal bracket-to-instrument panel nuts to 34 Nm (25 ft. lbs.). 4. Install new stop lamp switch. 5. Connect brake booster rod to brake pedal. Install retainer clip (Fig. 20). 6. Loosen adjustment screw (Fig. 24). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 7. Connect clutch master cylinder pushrod. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.). 8. Connect interlock/upstop and stop lamp switch connectors. 9. Install left lower instrument panel bezel (Fig. 19). 10. Connect battery negative cable. 11. Verify proper switch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 961 Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - RHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - RHD 1. Disconnect the master cylinder push rod from the pedal pin (Fig. 23). Inspect push rod retainer for damage. If it is damaged (broken/cracked), it must be replaced. 2. Squeeze together the tangs on the switch cover plate and slide the plate off the switch housing. 3. Disconnect the clutch interlock/upstop switch connector from the instrument panel wiring harness. 4. Remove the switch from the vehicle. INSTALLATION - RHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals. 1. Install the clutch interlock/upstop switch onto the master cylinder push rod, making sure that the push rod is oriented with the push rod retainer toward the wiring of the switch. The master cylinder push rod must be snapped into the clutch interlock/upstop switch along the smaller diameter of the push rod between the snap ring and the transition to the larger diameter. CAUTION: Improper assembly of the larger diameter of the push rod into the clutch interlock/upstop switch could cause damage to the switch or a clutch system failure. 2. Install the switch cover plate. CAUTION: Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked), it MUST be replaced. 3. Connect clutch master cylinder pushrod to the clutch pedal pin. 4. Route the wiring harness as it was prior to removal. 5. Secure the switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair "For information regarding this component please refer to steering column service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation Power Steering Fluid Level Sensor/Switch: Description and Operation POWER STEERING PRESSURE SWITCH DESCRIPTION A power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality by causing a readjustment of the engine idle speed as necessary when increased fluid pressure is sensed in the power steering system. The pressure switch functions by signaling the powertrain control module that an increase in pressure of the power steering system is putting additional load on the engine. This type of condition exists when the front tires of the vehicle are turned while the vehicle is stationary and the engine is at idle speed. When the powertrain control module receives the signal from the power steering pressure switch, it directs the engine to increase its idle speed. This increase in engine idle speed compensates for the additional load, thus maintaining the required engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The switch provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. When power steering pump pressure exceeds 2758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. The PCM sends 12 volts through a resister to the sensor circuit to ground. When pump pressure is low, the switch is closed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 971 Power Steering Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding, Refer to Service Precautions . 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise the vehicle. 3. Locate the power steering fluid pressure switch on the back side of the power steering gear. 4. Remove the vehicle wiring harness connector from the power steering fluid pressure switch. NOTE: When removing and installing the power steering pressure switch, use a 7/8 inch deep well socket. The deep well socket will prevent damage to the plastic electrical connector area of the power steering fluid pressure switch. 5. Unscrew and remove the power steering fluid pressure switch from the power steering gear. INSTALLATION 1. By hand, screw the power steering pressure switch into the power steering gear until it is fully seated. Tighten the power steering pressure switch to a maximum torque of 8 Nm (70 inch lbs.). Over-torquing will result in stripping the threads out of the power steering pressure switch port in the steering gear. 2. Install the vehicle wiring harness connector. Be sure the latch on the wiring harness connector is fully engaged with the locking tab on the power steering pressure switch. 3. Lower the vehicle. 4. Fill the power steering fluid reservoir to the correct fluid level. 5. Connect the negative cable to the negative post of the battery. 6. Start the engine and turn the steering wheel several times stop-to-stop to bleed any air from the fluid in the power steering system. Stop the engine, check the fluid level, and inspect the system for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 976 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 977 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 978 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 979 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications Solenoid/Pressure Switch Assembly-to-Case Bolt ................................................................................................................................ 12 Nm (110 in. lbs.) Solenoid/Pressure Switch Assembly Connector Screw ............................................................................................................................. 4 Nm (35 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 988 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 989 Fluid Pressure Sensor/Switch: Description and Operation 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 289) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 990 The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the chart shown. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate DTC will set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 991 Pressure Switch States Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 992 Fluid Pressure Sensor/Switch: Service and Repair 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 290). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 291). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 993 7. Remove solenoid/pressure switch assembly and gasket (Fig. 292). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 292). 2. Install and torque three (3) bolts (Fig. 291) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 290) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner/throttle body assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Interlock Mechanism Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 997 Shift Interlock Switch: Service and Repair REMOVAL Fig. 39 1. Remove the steering column lower cover (Fig. 39). Fig. 40 2. Remove the steering column upper and lower shrouds (Fig. 40). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 998 Fig. 41 3. Turn the ignition key to the "OFF" or "ON/ RUN" position (Fig. 41). Fig. 42 4. Grasp the interlock cable and connector firmly. Remove the interlock cable (Fig. 42). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 999 Fig. 43 5. Remove the two interlock mechanism-to-steering column attaching screws (Fig. 43). Remove the interlock housing. INSTALLATION 1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 Nm (21 inch lbs.). 2. Snap the interlock cable into the housing. 3. Install steering column upper and lower shrouds (Fig. 40). 4. Install steering column lower cover (Fig. 39). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations > Page 1003 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 1007 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 1008 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 1009 Autostick Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 1015 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 1016 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 1017 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 1018 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 1019 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 1020 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 1021 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1026 Transmission Speed Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1027 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1028 Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 293), sealed with an O-ring (Fig. 294), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 1031 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 295), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 1032 Transmission Speed Sensor: Description and Operation Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 298), sealed with an O-ring (Fig. 299), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 1033 OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 300), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 1034 Transmission Speed Sensor: Description and Operation Vehicle Speed Signal 41TE - Automatic Transmission VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 296). 5. Inspect speed sensor O-ring (Fig. 297) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Install air cleaner/throttle body assembly. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 1037 Transmission Speed Sensor: Service and Repair Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 301). 5. Inspect speed sensor O-ring (Fig. 302) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 302). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor ......................................................................................................................... ..................................................... 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 1042 Transmission Speed Sensor: Description and Operation T350 - Manual Transmission DESCRIPTION - VEHICLE SPEED SENSOR 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 1043 Transmission Speed Sensor: Service and Repair T350 - Manual Transmission VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector (Fig. 151). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt (Fig. 151). 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. Install pinion gear to speed sensor (Fig. 151). 2. Using a NEW O-ring, install the speed sensor to the transaxle (Fig. 151). 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector (Fig. 151). 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 1048 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 1049 Rear Window Defogger Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 1050 Heated Glass Element Switch: Testing and Inspection The rear window defogger switch may be tested in the vehicle or out of the vehicle, on the bench. IN-VEHICLE TESTING 1. Remove the switch from the instrument panel but leave the switch connected. 2. Turn the ignition switch ON. Rear Window Defogger Switch Harness Connector 3. Using a voltmeter, check for battery voltage at Pin 1 and 2. a. If OK, go to Step 4. b. If NOT OK, check fuse 7 in the fuse block and the 40 Amp cartridge 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. 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. BENCH TESTING 1. First remove switch. Rear Window Defogger Switch Connector 2. With switch removed from vehicle, use a jumper wire and connect a 12 volt supply to Pin 1 and 2. Using a third jumper wire, ground Pin 3. Refer to and the Rear Window Defogger Switch and Harness Connector Pin Call-Outs table. 3. Follow the same procedures used for IN-VEHICLE TESTING, except for step Step 2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door (Driver) - RHD Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1054 Door (Passenger) - LHD Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1055 Power Window Switch: Diagrams Driver Power Window Switch C1 Driver Power Window Switch C2 Passenger Power Window Switch (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1056 Passenger Power Window Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1057 Power Window Switch: Testing and Inspection Power Window Switch Continuity Remove the switch from its mounting, (Refer to POWER WINDOWS/POWER WINDOW SWITCH REMOVAL). Using an ohmmeter, test the window switch for continuity in all positions Refer to Power Window Switch Continuity table to determine if continuity is correct. If the correct results are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1058 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on window switch bezel and remove from door trim panel. 3. Disconnect wire connector from switch. 4. Remove two switch retaining screws. INSTALLATION 1. install the switch retaining screws. 2. Reconnect the wire connector to the switch. 3. Insert switch into the door trim panel. 4. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Wiper/Washer Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1063 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Replacement Fig.15 Wiper/Washer Switch REMOVAL 1. Remove the Multi-Function Switch from the vehicle Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 2. Remove the two retaining screws to the Wiper/Washer Switch. 3. Separate the two switches. INSTALLATION 1. Attach the two switches. 2. Install the two retaining screws to the Wiper/ Washer Switch. 3. Install the Multi-Function Switch from the vehicle. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1067 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1068 Wiper/Washer Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1069 Wiper Switch: Service and Repair Fig.15 Wiper/Washer Switch REMOVAL 1. Remove the Multi-Function Switch from the vehicle Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 2. Remove the two retaining screws to the Wiper/Washer Switch. 3. Separate the two switches. INSTALLATION 1. Attach the two switches. 2. Install the two retaining screws to the Wiper/ Washer Switch. 3. Install the Multi-Function Switch from the vehicle. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications Alignment Specifications Alignment Specifications CURB HEIGHT FRONT REAR All Neon 26.46 ± 0.32 in (672 ± 8 mm) 26.73 ± 0.32 in. (679 ± 8 mm) SRT-4 26.97 ± 0.32 in. (685 ± 8 mm) 27.44 ± 0.32 in. (697 ± 8 mm) FRONT WHEEL ALIGNMENT ITEM PREFERRED SETTING ACCEPTABLE RANGE Standard Neon Camber 0.00° -0.40° to +0.40° Cross Camber (Max Side-to-Side Difference) 0.00° 0.50° Caster +2.60° +1.60° to +3.60° Cross Caster (Max Side-to-Side Difference) 0.00° 1.00° Total Toe +0.20° 0.00° to +0.40° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. ACR Neon Camber 0.00° -2.4° to +0.40° Cross Camber (Max Side-to-Side Difference) 0.00° 0.50° Caster +2.60° +1.60° to +3.60° Cross Caster (Max Side-to-Side Difference) 0.00° 1.00° Total Toe +0.20° -0.70° to +0.30° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. REAR WHEEL ALIGNMENT ITEM PREFERRED SETTING ACCEPTABLE RANGE Standard Neon Camber -0.25° -0.65° to +0.15° Total Toe +0.30° +0.10° to +0.50° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. Thrust Angle 0.00° -0.10° to +0.10° ACR Neon Camber -0.25° -1.00° to +0.20° Total Toe +0.30° -0.70° to +0.30° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1074 setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. Thrust Angle 0.00° -0.10° to +0.10° Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1075 Alignment: Description and Operation DESCRIPTION - WHEEL ALIGNMENT Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when Daimler Chrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front ^ Camber (when proper alignment package is used) ^ Toe Rear ^ Camber (when proper alignment package is used) ^ Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement. Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. ^ Excessive negative camber will cause tread wear at the inside of the tire. ^ Excessive positive camber will cause tread wear on the outside of the tire. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1076 CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is + 0.3° and the right camber is 0.00°, the cross camber would be + 0.3°. CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. ^ Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. ^ Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. TOE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1077 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. ^ Toe-in is produced when the front edges of the wheels on the same axle are closer together than the rear edges. ^ Toe-out is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equally distant. TOE-OUT ON TURNS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1078 Toe-out on turns is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S. A. I.) Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1079 center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I. A.) Included angle is the sum of the S.A.I. angle plus or minus the camber angle, depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I. angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). ^ Negative thrust angle means the rear tires are tracking to the left of the front tires. ^ Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment PRE-WHEEL ALIGNMENT VEHICLE INSPECTION CAUTION: If during the inspection the front suspension crossmember shows any sign of impact damage, the steering column lower coupling must be inspected. Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the 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. WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. 4. If the rear alignment is out of specification, adjust it first before proceeding to the front. CAMBER AND CASTER Front and rear camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If either front or rear camber is found not to meet alignment specifications, it can be adjusted using an available camber adjustment bolt package. Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension components for any signs of damage or bending. No adjustment can be made to the caster setting on this vehicle. If the vehicle's caster is not within alignment specifications, check for damaged suspension components or body parts. CAUTION: Do not attempt to adjust the vehicles wheel alignment by heating or bending any of the suspension components. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION (WITHOUT ACR PACKAGE) NOTE: The following procedure should be used on vehicles WITHOUT the ACR competition package or on the rear suspension of vehicles with the ACR competition package. The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provides approximately one degree of camber adjustment per side of the vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below. CAUTION: There are separate camber adjustment bolt packages for the front and rear of the vehicle. Be sure to use the correct package. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1082 2. Remove the wheel and tire assembly at the strut requiring modification. 3. Remove the original upper bolt attaching the strut clevis bracket to the knuckle. 4. Install a bolt from the adjustment package into the hole where the original bolt was removed. Install the bolt from the rear. 5. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allowing the knuckle to slide in the clevis bracket. 6. Remove the original lower bolt. 7. Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket. Install the bolt from the rear. 8. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug. 9. Reinstall the tire and wheel assembly. 10. Perform the above procedure to any of the remaining struts as required. 11. Lower the vehicle and jounce the front and rear of the vehicle. 12. Adjust the front or rear camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis bracket bolts. Again jounce the front and rear of the vehicle, then verify the camber settings. 13. Torque front strut clevis bracket-to-steering knuckle attaching bolts to 53 Nm (40 ft. lbs.), plus an additional 1/4 turn after the torque is met. Torque the rear strut clevis bracket-to-rear knuckle attaching bolts to 95 Nm (70 ft. lbs.). 14. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to TOE within this wheel alignment service procedure. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION (WITH ACR PACKAGE) NOTE: The following procedure should only be used on the front suspension of vehicles WITH the ACR competition package. For installation of the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1083 adjustment bolt package on the ACR rear suspension, refer to CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION (WITHOUT ACR PACKAGE) above. The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provides approximately one degree of camber adjustment per side of the vehicle. Additional modification will also be necessary to gain a proper camber setting for ACR competition. To modify the strut, install and adjust the camber adjustment bolt package, follow the procedure below. CAUTION: There are separate camber adjustment bolt packages for the front and rear of the vehicle. Be sure to use the correct package for the front suspension. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. 2. Remove the wheel and tire assembly at the strut requiring modification. 3. Remove the original upper and lower bolts attaching the strut clevis bracket to the knuckle. 4. Separate the knuckle from the strut clevis bracket. NOTE: The following two steps must be performed to gain the necessary amount of negative camber for ACR competition. 5. Draw an imaginary line from the center of the clevis bracket upper bolt hole down through the center of the clevis bracket lower bolt hole. Pivoting the line at the center of the lower hole, move the upper end of the line inward so as to follow an arc past the inner edge of the upper bolt hole approximately 2.8 mm (0.11 inch). Mark the bracket showing what area of the surface needs to be removed to form the elongated hole. Remember, this elongation must follow the arc. Repeat this step on the opposite side of the clevis bracket. 6. Using an appropriate grinding tool, elongate the upper hole as indicated by the markings until the necessary material is removed. Repeat this step on the opposite side of the clevis bracket. 7. Place the knuckle back in the clevis bracket. 8. Install bolts from the adjustment package into the holes where the original bolts were removed. Install the bolts from the rear. 9. Install a nut provided in adjustment package on each replacement bolt. Tighten the nuts until snug, but still allowing the knuckle to slide in the clevis bracket. 10. Reinstall the tire and wheel assembly. 11. Perform the above procedure to the remaining front strut as required. 12. Lower the vehicle and jounce the front and rear of the vehicle. 13. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis bracket bolts. Again jounce the front and rear of the vehicle, then verify the camber settings. 14. Torque front strut clevis bracket-to-steering knuckle attaching bolts to 53 Nm (40 ft. lbs.), plus an additional 1/4 turn after the torque is met. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1084 Torque the rear strut clevis bracket-to-rear knuckle attaching bolts to 95 Nm (70 ft. lbs.). 15. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When performing the toe setting procedure, make sure the rear toe is set to the preferred specification before setting the front toe to the preferred specification. REAR TOE 1. Loosen the nuts on the left and right rear lateral link attaching bolts at the rear crossmember as necessary to allow rotation of the rear toe adjustment cams. CAUTION: When adjusting rear toe, the notches on the toe adjustment cams are not to be facing down. The notches in the adjustment cams are only to be facing up or toward one side. 2. Rotate each toe adjustment cam until the preferred rear toe specification is obtained. 3. While holding the toe adjustment cams from turning, tighten the attaching bolt nuts. This will securely hold the adjustment cams in position. Tighten the attaching bolt nuts to a torque of 88 Nm (65 ft. lbs.). 4. Proceed to FRONT TOE to set the front toe. FRONT TOE CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie rod during the front toe adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1085 1. Loosen the tie rod adjusting jam nuts. Grasp each inner tie rod at its hex and rotate it one way or the other until the front wheel toe is set to the preferred specification. 2. Tighten tie rod adjusting jam nuts to a torque of 75 Nm (55 ft. lbs.). 3. Make sure the inner tie rod-to-steering gear rubber boots are not twisted. If twisted, loosen the boot clamp at the inner tie rod and move the boot as necessary. 4. Remove steering wheel clamp. 5. Remove the alignment equipment. 6. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1086 Alignment: Service and Repair Curb Height Measurement MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front an rear of the vehicle should be jounced. Induce jounce by grasping the center of the rear, then front bumper (or fascia) and jouncing the vehicle an equal number of times. Release the bumper at the bottom of the jounce cycle. 1. Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, maximum left-to-right differential is not to exceed 10 mm (0.39 inch). 3. Compare the measurements to specifications listed in the CURB HEIGHT SPECIFICATIONS chart. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE ............................................................................................................................... ......................................... 400 ± 34 kPa (58 ± 5 psi) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1091 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1092 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1093 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 AIR CLEANER ELEMENT REMOVAL 1. Remove 5 screws from air cleaner element box lid. 2. Remove lid from air cleaner box. 3. Pull air cleaner up and out of air cleaner box. INSTALLATION 1. Install air cleaner element on to throttle body and push towards the throttle body and past lip in air cleaner box bottom (Fig. 10). 2. Install lid and tighten screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1105 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1109 The electronic ignition coil pack attaches directly to the valve cover. The 2.0 Liter (122 cu. inch) in-line four cylinder engine is a single over head camshaft with hydraulic lifters and four valves per cylinder design (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE ................................................................................................................................................. ........................................................ RESISTANCE # 1, # 4 ................................................................................................................................................. ..................................................... 2970 - 8910 ohms # 2, # 3 ................................................................................................................................................. ..................................................... 2360 - 7070 ohms Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1117 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature silicone materials. All spark plug cable leads are properly identified with cylinder numbers. The inside of most the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1118 Ignition Cable: Service and Repair REMOVAL 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. Remove spark plug cable from coil first. 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. INSTALLATION 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. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair Spark Plug Tube: Service and Repair SPARK PLUG TUBE REMOVAL 1. Remove the cylinder head cover. 2. Using locking pliers, remove the tube from the cylinder head. Discard old tube. INSTALLATION 1. Clean area around spark plug with Mopar parts cleaner or equivalent. 2. Apply Mopar Stud and Bearing Mount or equivalent to a new tube approximately 1 mm (0.039 inch) from the end in a 3 mm (0.118 inch) wide area. 3. Install sealer end of tube into the cylinder head. Then carefully install the tube using a hardwood block and mallet until the tube is seated into the bottom of the bore. 4. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation Spark Plug Tube Seal - Valve Cover: Description and Operation DESCRIPTION The spark plug tube seals are located in the cylinder head cover. These seals are pressed into the cylinder head cover to seal the outside perimeter of the spark plug tubes. If these seals show signs of hardness and/or cracking, they should be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation > Page 1126 Spark Plug Tube Seal - Valve Cover: Service and Repair REMOVAL 1. Remove the cylinder head cover. 2. Using an appropriate tool, carefully remove spark plug tube seals. Care should be taken not to damage cylinder head cover sealing surfaces. INSTALLATION 1. Clean all sealing surfaces. NOTE: Position seal with the concave side facing the installation tool. 2. Install seals using Special Tool MB-998306. Only hand pressure on tool is needed to install new seals. 3. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25 percent Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1130 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRB III. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications Timing Belt: Specifications Timing Belt Replacement Interval On 2000-02 Neon models, replace every 105,000 miles or 84 months in normal service, or every 105,000 miles in severe service. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation Timing Belt: Service and Repair Installation With Mechanical Tensioner TIMING BELT (WITH MECHANICAL TENSIONER) 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC (Fig. 178). 2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear timing belt cover (Fig. 179). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1139 3. Move crankshaft to 1/2 mark before TDC (Fig. 180) for belt installation. 4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket, then around the camshaft sprocket, and finally route the back side of the timing belt around the timing belt tensioner pulley 5. Move crankshaft sprocket to TDC to take up belt slack. 6. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate COUNTERCLOCKWISE. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang (Fig. 181). Using the allen wrench to prevent the top plate from moving, torque the tensioner lock nut to 30 Nm (22 ft. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued. 7. Remove allen wrench and torque wrench. NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1140 8. Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position (Fig. 183). 9. Check if the spring tang is within the tolerance window (Fig. 182). If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 6 through 8. 10. Install front timing belt cover. 11. Install spark plugs. 12. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB 1116 scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. With Hydraulic Tensioner Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1141 TIMING BELT (WITH HYDRAULIC TENSIONER) 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC (Fig. 173). 2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover (Fig. 174). 3. Move crankshaft to 1/2 mark before TDC (Fig. 175) for belt installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1142 4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket, then around the camshaft sprocket, and finally route the back side of the timing belt around the timing belt tensioner pulley 5. Move crankshaft sprocket to TDC to take up belt slack. 6. Re-set the hydraulic tensioner by placing tensioner body in a vise equipped with soft jaws (Fig. 176). Slowly compress the plunger. 7. Compress the plunger until a 1.9 mm (5/64) Allen wrench or pin can be inserted through the body and the plunger (Fig. 176). 8. Remove hydraulic tensioner from vise and install on engine. Do not tighten attaching bolts at this time. 9. Using a torque wrench on the tensioner pulley bolt, apply 28 Nm (250 in. lbs.) of torque against the timing belt. 10. With torque applied to the tensioner pulley/ timing belt, move the tensioner up against the pulley pivot bracket and tighten tensioner bolts to 31 Nm (23 ft. lbs.). (Fig. 177). 11. Pull the tensioner plunger retaining pin. Pretension is correct when the pin can be removed and installed into tensioner housing and plunger. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1143 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks (Fig. 175) and (Fig. 174). 13. Check belt tension by installing pin into tensioner housing. If pin cannot be re-installed, repeat belt tension procedure. 14. Install the front timing belt cover. 15. Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB III scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1144 Timing Belt: Service and Repair Removal With Mechanical Tensioner TIMING BELT (WITH MECHANICAL TENSIONER) 1. Remove front timing belt cover (Fig. 168). 2. Remove spark plugs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1145 CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine CLOCKWISE with the crankshaft (Fig. 183). 3. Loosen timing belt tensioner lock nut (Fig. 169). 4. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate CLOCKWISE until there is enough slack in timing belt to allow for removal (Fig. 169). 5. Remove timing belt. CAUTION: Do not rotate the camshaft once the timing belt has been removed or damage to valve components may occur. With Hydraulic Tensioner TIMING BELT (WITH HYDRAULIC TENSIONER) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1146 1. Remove front timing belt cover (Fig. 165). CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Installation > Page 1147 2. Rotate crankshaft until timing marks are aligned at both the camshaft and crankshaft (Fig. 166). 3. Loosen the timing belt tensioner fasteners (Fig. 166). CAUTION: DO NOT loosen, tighten, or remove the tensioner pivot bolt (Fig. 167). 4. Remove the timing belt from sprockets. CAUTION: Do not rotate the camshaft once the timing belt has been removed or damage to valve components may occur. 5. For timing belt tensioner pulley assembly removal Refer to TIMING BELT TENSIONER & PULLEY - REMOVAL. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Accessory drive belt Belt Tension Power Steering Pump & A/C Compressor Dynamic Tension Generator New 135 lbs. Used 70 lbs. A belt is considered used after 15 minutes of run-in time. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1151 Drive Belt: Description and Operation DESCRIPTION The accessory drive consist of two Poly-V type drive belts (Fig. 1). One belt drives the generator, the other drives the power steering pump and air conditioning compressor (if equipped). The power steering/ air conditioning belt is tensioned by an automatically controlled belt tensioner. The generator belt is manually tensioned using an adjusting bolt and a locking nut. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1152 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt Drive Belt: Service and Repair A/C Compressor / Power Steering Pump Belt REMOVAL POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 3). CLEANING Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1155 Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1156 1. Install the drive belt (Fig. 3) over all the pulleys except for the power steering pump pulley 2. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be installed on the power steering pulley Release spring tension onto belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1157 3. After belt is installed, inspect belt length indicator marks (Fig. 7). The indicator mark should be within the minimum belt length and maximum belt length marks. On a new belt, the indicator mark should align approximately with the nominal belt length mark. DRIVE BELT TENSION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1158 Drive Belt: Service and Repair Alternator/Generator Belt REMOVAL GENERATOR BELT 1. Remove power steering pump/air conditioning compressor drive belt. 2. Loosen generator locking nut (Fig. 4). 3. Raise vehicle on hoist. 4. Remove accessory drive belt splash shield (Fig. 5). 5. Loosen generator pivot bolt (Fig. 4). 6. Loosen generator adjusting bolt until generator belt can be removed (Fig. 4). 7. Remove generator belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1159 CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. GENERATOR BELT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1160 1. Install belt around pulleys (Fig. 3). 2. Adjust belt tension by tightening adjusting bolt (Fig. 4). Adjust belt to specification shown in DRIVE BELT TENSION CHART. 3. Check belt tension using Special Tool 8371 Belt Tension Gauge Adapter, and the DRB III using the following procedures: WARNING: DO NOT CHECK BELT TENSION WITH ENGINE RUNNING. a. Connect 8371 to the DRB III following the instructions provided with tool. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1161 b. Place end of microphone probe approximately 2.54 cm (1 inch) from belt at one of the belt center span locations shown in (Fig. 8). c. Pluck the belt a minimum of 3 times. (Use your finger or other suitable tool) d. The frequency of the belt in hertz (Hz) will display on DRB III screen. e. Adjust belt to obtain proper frequency (tension). 4. Tighten generator pivot bolt to 54 Nm (40 ft. lbs.) (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1162 5. Install accessory drive belt splash shield (Fig. 5). 6. Lower vehicle. 7. Tighten generator locking nut to 54 Nm (40 ft. lbs.) (Fig. 4). 8. Install power steering pump/air conditioning compressor drive belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1163 DRIVE BELT TENSION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1164 Drive Belt: Service and Repair Power Steering Belt REMOVAL POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 3). CLEANING Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1165 Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1166 1. Install the drive belt (Fig. 3) over all the pulleys except for the power steering pump pulley 2. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be installed on the power steering pulley Release spring tension onto belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1167 3. After belt is installed, inspect belt length indicator marks (Fig. 7). The indicator mark should be within the minimum belt length and maximum belt length marks. On a new belt, the indicator mark should align approximately with the nominal belt length mark. DRIVE BELT TENSION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT REMOVAL 1. Remove 5 screws from air cleaner element box lid. 2. Remove lid from air cleaner box. 3. Pull air cleaner up and out of air cleaner box. INSTALLATION 1. Install air cleaner element on to throttle body and push towards the throttle body and past lip in air cleaner box bottom (Fig. 10). 2. Install lid and tighten screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 182). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 in. lbs.). 5. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1179 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1184 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair INLET FILTER REPLACEMENT REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Fig.28 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 28). 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 15 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1191 Oil Filter: Service and Repair OIL FILTER REMOVAL CAUTION: When servicing the oil filter (Fig. 116), avoid deforming the filter. Use an appropriate oil filter removing tool. Position filter wrench strap close the seam at the base of the filter. The oil filter seam that joins the can to the base, is reinforced by the base plate. 1. Turn filter counterclockwise to remove (Fig. 116). INSTALLATION 1. Clean and check the filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. 2. Lubricate new filter gasket. 3. Screw filter on until gasket contacts base (Fig. 116). Tighten to 21 Nm (15 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service Precautions Refrigerant Filter: Service Precautions WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THE OPERATION. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service Precautions > Page 1195 Refrigerant Filter: Service and Repair REMOVAL The filter/drier is mounted in a rubber grommet on the left 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. 1. Evacuate and recover the refrigerant. Fig.30 Heater Hose Assembly - RHD 2.0L 2. Disconnect liquid line from filter/drier. 3. Disconnect liquid line on suction line assembly from filter/drier. 4. Pull filter/drier out of rubber grommet. 5. Remove the filter/drier. INSTALLATION 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. NOTE: Replace all A/C line seals from disassembled components. Failure to replace seals could result in a refrigerant leak. 1. Install the filter/drier in the rubber grommet. 2. Connect the liquid line to the filter/drier. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service Precautions > Page 1196 3. Connect the liquid line on the suction line assembly to the filter/drier. 4. Evacuate the refrigerant system. 5. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water Pump Inlet Tube to Engine Block-Bolts 105 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications > Page 1201 Coolant Line/Hose: Description and Operation WATER PUMP INLET TUBE DESCRIPTION The water pump inlet tube connects the water pump housing to the radiator lower hose and heater return hose. This plastic tube is sealed by an O-ring and held in place by fasteners to the block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Heater Supply/Return Tubes Coolant Line/Hose: Service and Repair Heater Supply/Return Tubes HEATER SUPPLY RETURN TUBES REMOVAL NOTE: It is not necessary to remove the intake manifold to replace heater supply/return tubes. 1. Disconnect negative battery cable. Disconnect positive battery cable. Remove battery. 2. Raise vehicle on hoist. 3. Drain cooling system. 4. Remove hose clamp from heater return tube located near starter. Disconnect hose from tube. 5. Lower vehicle 6. Remove air cleaner housing and throttle body to intake manifold hose. 7. Disconnect PCV vacuum hose at intake manifold. 8. Remove hose clamp from heater supply tube located near thermostat housing. Disconnect hose from tube. 9. Remove two heater hose clamps and disconnect heater hoses near battery. 10. Unclip wiring harness from heater tube assembly 11. Remove transmission dipstick tube and place an appropriate plug into hole to prevent coolant from entering transmission. 12. Remove fasteners attaching heater tube assembly to cylinder head and engine block. 13. Remove heater tube assembly. NOTE: After heater tube assembly is removed, the short hoses connecting the tubes to the thermostat housing and water pump inlet tube can be replaced at this time. INSTALLATION 1. Inspect all hoses that connect to heater tubes. Replace if necessary. 2. Position heater tube assembly near it's mounting location. 3. Connect hoses at water pump inlet tube and thermostat housing. Ensure clamps are positioned properly to seal hoses and avoid contact with engine components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Heater Supply/Return Tubes > Page 1204 4. Install fasteners attaching heater tube assembly to cylinder head and engine block. NOTE: Before installing transmission dipstick tube clean any residual coolant from around the area where plug was placed. 5. Remove plug from transmission dipstick tube mounting hole. Install transmission dipstick tube. 6. Reattach wiring harness to heater tube assembly. 7. Connect two heater hoses to heater tubes near battery. Ensure clamps are positioned properly to seal hoses and avoid contact with engine components. 8. Connect PCV vacuum hose to intake manifold. 9. Install air cleaner housing and throttle body to intake manifold hose. 10. Raise vehicle on hoist. 11. Close radiator draincock. 12. Lower vehicle 13. Install battery. Connect positive battery cable. Connect negative battery cable. 14. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Heater Supply/Return Tubes > Page 1205 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube WATER PUMP INLET TUBE REMOVAL 1. Drain the cooling system. 2. Remove the radiator upper hose to access the hose connections at the inlet tube. 3. Remove the intake manifold. CAUTION: Do not use any sharp tools to remove hoses from inlet tube. This may cause the tube to leak. 4. Remove the radiator lower hose and heater hose from the inlet tube. 5. Remove the lower intake manifold support bracket. 6. Remove the inlet tube to the block fasteners. 7. 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 Mopar Dielectric Grease and install inlet tube into the cylinder block opening. 3. Install inlet tube fasteners and tighten to 12 Nm (105 in. lbs.). 4. Install intake manifold lower support bracket fasteners and tighten to 12 Nm (105 in. lbs.). 5. Connect the radiator lower hose and heater hose to inlet tube. 6. Install the intake manifold. 7. Install the radiator upper hose. 8. Fill the cooling system. 9. Pressure test cooling system and check for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service Precautions Heater Hose: Service Precautions 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. - When installing hoses to heater core inlet or outlet nipples DO NOT exert excessive pressure. The heater core may become damaged and leak engine coolant. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement - LHD HEATER INLET HOSE - LHD 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. Fig.54 Heater Hose Assembly - LHD 2.0L (Typical 2.4L) 2. Using spring tension clamp pliers (or equivalent), to remove clamps at end of heater hose to be removed. 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Heater Inlet Hose Replacement - RHD HEATER INLET HOSE - RHD 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1211 1. Drain engine cooling system. Fig.46 Heater Hose Assembly - RHD 2.0L 2. Using spring tension clamp pliers (or equivalent), to remove clamps at end of heater hose to be removed 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1212 Heater Hose: Service and Repair Heater Return Hose Replacement Heater Return Hose Replacement - LHD HEATER RETURN HOSE - LHD CAUTION: When removing hoses from the heater core inlet nipples DO NOT exert excessive 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. Fig.54 Heater Hose Assembly - LHD 2.0L (Typical 2.4L) 2. Using spring tension clamp pliers (or equivalent), to remove the clamps at the end of the heater hoses to be removed. 3. Carefully rotate the hose back and forth while pulling away from the connector nipple. INSTALLATION CAUTION: When installing hoses to heater core inlet or outlet nipples DO NOT exert excessive pressure. The heater core may become damaged and leak engine coolant. 1. Carefully rotate the hose back and forth while pushing the hose onto the connector nipple. 2. Using spring tension pliers, install the clamps at the end of the heater hose being installed. 3. Refill the cooling system. Heater Return Hose Replacement - RHD HEATER RETURN HOSE - RHD CAUTION: When removing hoses from the heater core inlet nipples DO NOT exert excessive pressure. The heater core may become damaged and Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1213 leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. Fig.46 Heater Hose Assembly - RHD 2.0L 2. Using spring tension clamp pliers (or equivalent), to remove the clamps at the end of the heater hoses to be removed. 3. Carefully rotate the hose back and forth while pulling away from the connector nipple. INSTALLATION 1. Carefully rotate the hose back and forth while pushing the hose onto the connector nipple. 2. Using spring tension pliers, install the clamps at the end of the heater hose being installed. 3. Refill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Line Retainer Bolt ..................................................................................................................................................... 23 Nm (16.9 ft. lbs) (203 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Technician Safety Information Hose/Line HVAC: Technician Safety Information WARNING: - THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THE OPERATION. - REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Technician Safety Information > Page 1219 Hose/Line HVAC: Vehicle Damage Warnings CAUTION: - The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. - 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line Hose/Line HVAC: Description and Operation A/C Discharge Hose/Line A/C Discharge Line - LHD Fig.43 A/C Compressor Lines The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. A/C Discharge Line - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1222 Fig.44 A/C Compressor Lines The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1223 Hose/Line HVAC: Description and Operation A/C Liquid Hose/Line Liquid Line - LHD The liquid line is the line that goes from the condenser to the receiver-drier. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. Liquid Line - RHD The liquid line is the line that goes from the condenser to the receiver-drier. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1224 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line Suction Line - LHD 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 O-rings on all other connections. There are no serviceable parts on the suction line other than the rubber O-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. The refrigerant lines used for this vehicle are common between the two optional engines in order to reduce complexity. The following refrigerant lines are available for service replacement on this vehicle: Fig.60 A/C Compressor Lines - LHD - Discharge line - The discharge line is a flexible hose type line that is connected from the discharge port of the compressor to the inlet (upper fitting) of the condenser. It has no serviceable parts except the rubber O-ring seals used on the fittings at each end of the line. If the discharge line is damaged or faulty, it must be replaced. - Liquid line - The liquid line is a flexible hose type line that is connected between the outlet (lower fitting) of the condenser and the mid-line connector block of the suction and liquid line assembly. The liquid line also contains the variable orifice valve. It has no serviceable parts except the rubber O-ring seals used on the fittings at each end of the line. If the liquid line or the variable orifice valve are damaged or faulty, the liquid line unit must be replaced. - Suction line - The suction line is a flexible hose type line that is connected between the mid-line connector block of the suction and liquid line assembly and the suction port of the compressor. It has no serviceable parts except the rubber O-ring seals used on the fittings at each end of the line. If the suction line is damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1225 Fig.61 A/C Service Ports - (Typical) - Suction and liquid line assembly - The suction and liquid line assembly is a formed tubing type line assembly that includes the mid-line connector block, a connector block for the evaporator, inlet and outlet line fittings for the accumulator and both A/C service ports. The A/C service port caps, the A/C service port valve cores, the gasket used to seal the connector block at the evaporator and the rubber O-ring seals for the line fittings at the accumulator are all available for service replacement. If any other part of the suction and liquid line assembly is damaged or faulty, the assembly must be replaced. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant line connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Suction Line - RHD 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 O-rings on all other connections. There are no serviceable parts on the suction line other than the rubber O-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. The refrigerant lines used for this vehicle are common between the two optional engines in order to reduce complexity. The following refrigerant lines are available for service replacement on this vehicle: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1226 Fig.52 A/C Refrigerant Lines - Compressor - Discharge line - The discharge line is a flexible hose type line that is connected from the discharge port of the compressor to the inlet (upper fitting) of the condenser. It has no serviceable parts except the rubber 0-ring seals used on the fittings at each end of the line. If the discharge line is damaged or faulty, it must be replaced. - Liquid line - The liquid line is a flexible hose type line that is connected between the outlet (lower fitting) of the condenser and the mid-line connector block of the suction and liquid line assembly. The liquid line also contains the variable orifice valve. It has no serviceable parts except the rubber 0-ring seals used on the fittings at each end of the line. If the liquid line or the variable orifice valve are damaged or faulty, the liquid line unit must be replaced. - Suction line - The suction line is a flexible hose type line that is connected between the mid-line connector block of the suction and liquid line assembly and the suction port of the compressor. It has no serviceable parts except the rubber 0-ring seals used on the fittings at each end of the line. If the suction line is damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1227 Fig.53 A/C Service Ports - LHD Shown (Typical RHD) - Suction and liquid line assembly - The suction and liquid line assembly is a formed tubing type line assembly that includes the mid-line connector block, a connector block for the evaporator, inlet and outlet line fittings for the accumulator and both A/C service ports. The A/C service port caps, the A/C service port valve cores, the gasket used to seal the connector block at the evaporator and the rubber 0-ring seals for the line fittings at the accumulator are all available for service replacement. If any other part of the suction and liquid line assembly is damaged or faulty, the assembly must be replaced. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant line connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement A/C Discharge Line Replacement - LHD REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system Fig.44 Discharge Line 2. From the top side of the vehicle, remove line at compressor. 3. From the bottom side of the vehicle, remove line at condenser. INSTALLATION WARNING: THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Position the A/C discharge line in the vehicle and install the condenser end. Tighten the connections to 12 Nm (108 in. lbs.) 2. Lower the vehicle and install the compressor end of the discharge line. Tighten the connections to 12 Nm ( 108 in. lbs.) 3. Evacuate the refrigerant system. 4. Recharge the A/C system. A/C Discharge Line Replacement - RHD WARNING: THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1230 Fig.45 High Pressure Cut Out Switch Location 2. From the top side of the vehicle, remove line at compressor. 3. From the bottom side of the vehicle, remove line at condenser. INSTALLATION 1. Position the A/C discharge line in the vehicle and install the condenser end. Tighten the connections to 12 Nm (108 in. lbs.) 2. Lower the vehicle and install the compressor end of the discharge line. Tighten the connections to 12 Nm ( 108 in. lbs.) 3. Evacuate the refrigerant system. 4. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1231 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Liquid Line Replacement - LHD WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system 2. Disconnect liquid line at drier. 3. Disconnect liquid line at condenser. 4. Remove the liquid line. INSTALLATION NOTE: Replacement of ale line seals is required anytime connections are opened. Failure to replace seals could result in a refrigerant leak. 1. Connect the liquid line at the drier. 2. Connect the liquid line at the condenser. 3. Evacuate the A/C system. 4. Recharge the refrigerant system. Liquid Line Replacement - RHD WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. 2. Disconnect liquid line at drier. 3. Disconnect liquid line at condenser. 4. Remove the liquid line. INSTALLATION NOTE: Replacement of a/c line seals is required anytime connections are opened. Failure to replace seals could result in a refrigerant leak. 1. Connect the liquid line at the drier. 2. Connect the liquid line at the condenser. 3. Evacuate the A/C system. 4. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1232 Hose/Line HVAC: Service and Repair A/C Suction and Liquid Hose/Line Replacement Suction and Liquid Line Replacement - LHD WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the battery negative cable. 3. If the vehicle is so equipped, relocate the vehicle speed control servo as necessary to access the accumulator. Refer to Vehicle Speed Control System for the proper procedures. Fig.64 A/C Accumulator And Low Pressure Switch 4. Remove the nut that secures the liquid line fitting (outboard fitting) to the mid-line connector block of the suction and liquid line assembly. 5. Disconnect the liquid line fitting from the mid-line connector block of the suction and liquid line assembly. 6. Remove the rubber O-ring seal from the refrigerant line fitting of the liquid line and discard. 7. Install plugs in, or tape over the opened mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 8. Remove the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. 9. Disconnect the suction line fitting from the mid-line connector block of the suction and liquid line assembly. 10. Remove the rubber O-ring seal from the refrigerant line fitting of the suction line and discard. 11. Install plugs in, or tape over the opened mid-line connector block suction line port and the refrigerant line fitting of the suction line. 12. Remove the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 13. Disconnect the two refrigerant line fittings of the suction and liquid line assembly from the accumulator connector block inlet and outlet ports. 14. Remove the rubber O-ring seal from the refrigerant line fittings of the suction and liquid line assembly and discard. 15. Install plugs in, or tape over the opened accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 16. Remove the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. 17. Disconnect the suction and liquid line assembly evaporator connector block from the evaporator. 18. Remove the gasket from the suction and liquid line assembly evaporator connector block and discard. 19. Install plugs in, or tape over the opened suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 20. Remove the suction and liquid line assembly from the engine compartment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1233 INSTALLATION 1. Position the suction and liquid line assembly into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 3. Align the suction and liquid line assembly evaporator connector block and a new gasket to the evaporator inlet and outlet ports. 4. Install and tighten the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. Tighten the upper screw to 11.3 Nm (100 in. lbs.) first, then tighten the lower screw. 5. Remove the tape or plugs from the accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings of the suction and liquid line assembly. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 7. Reconnect the refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 8. Install and tighten the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. Tighten the screws to 2.3 Nm (20 in. lbs.). 9. Remove the tape or plugs from the mid-line connector block suction line port and the refrigerant line fitting of the suction line. 10. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the suction line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 11. Reconnect the suction line fitting to the mid-line connector block suction line port of the suction and liquid line assembly. 12. Install and tighten the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the nut to 4.5 Nm (40 in. lbs.). 13. Remove the tape or plugs from the mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the liquid line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 15. Reconnect the liquid line fitting to the mid-line connector block liquid line port of the suction and liquid line assembly. 16. Install and tighten the nut that secures the liquid line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the nut to 4.5 Nm (40 in. lbs.). 17. If the vehicle is so equipped, reinstall the vehicle speed control servo. Refer to Vehicle Speed Control System for the proper procedures. 18. Reconnect the battery negative cable. 19. Evacuate the refrigerant system. Refer to Refrigerant System Evacuate in this group for the proper procedures. 20. Charge the refrigerant system. Refer to Refrigerant System Charge in this group for the proper procedures. Suction and Liquid Line Replacement - RHD WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the battery negative cable. 3. If the vehicle is so equipped, relocate the vehicle speed control servo as necessary to access the accumulator. Refer to Vehicle Speed Control System for the proper procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1234 Fig.56 A/C Refrigerant Lines - Accumulator/Evaporator - LHD (Typical - RHD) 4. Remove the nut that secures the liquid line fitting (outboard fitting) to the mid-line connector block of the suction and liquid line assembly. 5. Disconnect the liquid line fitting from the mid-line connector block of the suction and liquid line assembly. 6. Remove the rubber O-ring seal from the refrigerant line fitting of the liquid line and discard. 7. Install plugs in, or tape over the opened mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 8. Remove the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. 9. Disconnect the suction line fitting from the mid-line connector block of the suction and liquid line assembly. 10. Remove the rubber O-ring seal from the refrigerant line fitting of the suction line and discard. 11. Install plugs in, or tape over the opened mid-line connector block suction line port and the refrigerant line fitting of the suction line. 12. Remove the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 13. Disconnect the two refrigerant line fittings of the suction and liquid line assembly from the accumulator connector block inlet and outlet ports. 14. Remove the rubber O-ring seal from the refrigerant line fittings of the suction and liquid line assembly and discard. 15. Install plugs in, or tape over the opened accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 16. Remove the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. 17. Disconnect the suction and liquid line assembly evaporator connector block from the evaporator. 18. Remove the gasket from the suction and liquid line assembly evaporator connector block and discard. 19. Install plugs in, or tape over the opened suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 20. Remove the suction and liquid line assembly from the engine compartment. INSTALLATION 1. Position the suction and liquid line assembly into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 3. Align the suction and liquid line assembly evaporator connector block and a new gasket to the evaporator inlet and outlet ports. 4. Install and tighten the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. Tighten the upper screw to 11.3 Nm (100 in. lbs.) first, then tighten the lower screw. 5. Remove the tape or plugs from the receiver-drier connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings of the suction and liquid line assembly. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 7. Reconnect the refrigerant line fittings of the suction and liquid line assembly to the receiver-drier connector block inlet and outlet ports. 8. Install and tighten the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the receiver-drier connector block inlet and outlet ports. Tighten the screws to 2.3 Nm (20 in. lbs.). 9. Remove the tape or plugs from the mid-line connector block suction line port and the refrigerant line fitting of the suction line. 10. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the suction line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 11. Reconnect the suction line fitting to the mid-line connector block suction line port of the suction and liquid line assembly. 12. Install and tighten the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1235 nut to 4.5 Nm (40 in. lbs.). 13. Remove the tape or plugs from the mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the liquid line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 15. Reconnect the liquid line fitting to the mid-line connector block liquid line port of the suction and liquid line assembly. 16. Install and tighten the nut that secures the liquid line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the nut to 4.5 Nm (40 in. lbs.). 17. If the vehicle is so equipped, reinstall the vehicle speed control servo. Refer to Vehicle Speed Control System for the proper procedures. 18. Reconnect the battery negative cable. 19. Evacuate the refrigerant system. 20. Charge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1236 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction Line Replacement - LHD REMOVAL WARNING: THE REFRIGERANT MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS. 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. Fig.62 A/C Compressor Lines - LHD 2. Remove line at the accumulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1237 Fig.63 A/C Compressor Lines - LHD 3. Remove line at the compressor. INSTALLATION WARNING: THE REFRIGERANT MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS. 1. Install the suction line at the compressor. 2. Install the suction line at the expansion valve. 3. Position the expansion valve and install the retaining bolt. 4. Evacuate the A/C system. 5. Recharge the refrigerant system. Suction Line Replacement - RHD WARNING: THE REFRIGERANT MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1238 Fig.54 Expansion Valve 2. Remove retaining bolt at expansion valve. 3. Remove line at the expansion valve. Fig.55 Accumulator And Lines - LHD (Typical - RHD) 4. Remove line at the compressor. INSTALLATION 1. Install the suction line at the compressor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1239 2. Install the suction line at the expansion valve. 3. Position the expansion valve and install the retaining bolt. 4. Evacuate the A/C system. 5. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ..................................................... 34 Nm (25 ft. lbs.) Return Hose Bracket Bolt .................................................................................................................................................. 28 Nm (21 ft. lbs., 250 inch lbs.) Pressure Hose Bracket Bolt ........................................................................ .............................................................................................. 61 Nm (45 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure HOSE POWER STEERING PRESSURE REMOVAL NOTE: Before proceeding, Service Precautions. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. Hoses And Cooler At LHD Gear Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1245 Hoses And Cooler At RHD Gear 3. Back out the tube nut securing the power steering fluid pressure hose to the gear. 4. LHD only Open the tube clamp on the right side of the gear and release the tube from the clamp. 5. Remove the pressure hose tube from the gear. RHD Pressure Hose At Engine 6. RHD only - Remove the bolt securing the pressure hose bracket to the engine. 7. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1246 Power Steering Hoses At Pump 8. Remove the bolt securing the hose routing bracket to the engine mount dragon head. Remove the hose from the bracket. 9. Un-thread the tube nut securing the power steering pressure hose to the power steering pump. 10. Remove the power steering pressure hose. INSTALLATION 1. Install the power steering pressure hose into the engine compartment from the top. First, guide the pump end of the hose under the pump, then route the rest of the hose along the right side of the engine. Guide the gear end of the hose down behind the engine towards the power steering gear. 2. Using a lint free towel, wipe clean the open power steering hose end and the power steering pump port. Replace the used O-ring with new. Lubricate the O-ring with clean power steering fluid. 3. Install the power steering pressure hose into the outlet fitting on the bottom of the power steering pump. 4. Thread the tube nut into the pump outlet fitting and tighten it to a torque of 34 Nm (25 ft. lbs.). 5. Install the hose into the hose routing bracket aligning it as shown and attach the bracket to the engine mount dragon head along with the ground strap. Tighten the screw to a torque of 12 Nm (105 inch lbs.). 6. Raise the vehicle. CAUTION: The power steering fluid hoses must remain away from the exhaust system, vehicle components, and unfriendly surfaces that can cause possible damage to the power steering hoses. 7. RHD only - Install the bolt attaching the power steering fluid pressure hose routing clamp to the engine. Tighten the bolt to a torque of 61 Nm (45 ft. lbs.). 8. Using a lint free towel, wipe clean the open power steering hose end and the power steering gear port. Replace the used O-ring with new. Lubricate the O-ring with clean power steering fluid. 9. Attach the power steering fluid pressure hose to the port on the power steering gear. Start the tube nut threads into the gear. Do not completely tighten at this time. 10. LHD only - Open the tube clamp on the right side of the gear and insert the pressure hose tube. Close the clamp. 11. Tighten the pressure hose tube nut at the gear to a torque of 34 Nm (25 ft. lbs.). 12. Lower the vehicle. 13. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. 14. Check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1247 Power Steering Line/Hose: Service and Repair Hose - Return HOSE POWER STEERING RETURN REMOVAL NOTE: Before proceeding, Service Precautions. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. Hoses And Cooler At LHD Gear Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1248 Hoses And Cooler At RHD Gear 3. Remove the hose clamp securing the return hose to the power steering cooler tube. Slide the hose off the end of the cooler tube. 4. Lower the vehicle. Power Steering Hoses At Pump 5. Remove the hose clamp securing the return hose to the power steering fluid reservoir. Slide the hose off the end of the reservoir fitting. 6. Remove the bolt securing the hose routing bracket to the engine mount dragon head. Remove the hose from the bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1249 INSTALLATION 1. Slide a hose clamp onto the power steering pump end of the hose far enough to clear the fitting on the power steering fluid reservoir once the hose is installed. 2. Install the power steering return hose into the engine compartment from the top. First, guide the pump end of the hose onto the fitting of the power steering pump fluid reservoir, then route the rest of the hose along the right side of the engine. Guide the remaining end of the hose down behind the engine towards the power steering gear. 3. Expand the hose clamp and slide it onto the fluid reservoir fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 4. Install the hose into the hose routing bracket aligning it as shown and attach the bracket to the engine mount dragon head along with the ground strap. Tighten the screw to a torque of 12 Nm (105 inch lbs.). 5. Raise the vehicle. CAUTION: The power steering fluid hoses must remain away from the exhaust system, vehicle components, and unfriendly surfaces that can cause possible damage to the power steering hoses. 6. Using a lint free towel, wipe clean the open power steering hose end and the power steering fluid cooler tube. 7. Install a hose clamp onto the end of the hose far enough to clear the fitting on the cooler once the hose is installed. 8. Slide the hose onto the end of the cooler tube. Install the hose clamp past the bead formed into the cooler tube and secure in place. 9. Lower the vehicle. 10. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. 11. Check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Bring the fluid level up to the requirements described on the side of the brake reservoir. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 1255 Brake Fluid: Fluid Type 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1256 Brake Fluid: Service Precautions WARNING: Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident. CAUTION: DO not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1257 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - 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 including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1258 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs are marked, FULL and MIN, indicating the allowable brake fluid level range in the master cylinder brake fluid reservoir. 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. Although there is a range, the preferred level is FULL. If necessary, adjust the brake fluid level to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications HYDRAULIC - FLUID CAUTION: Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system. NOTE: The clutch hydraulic system and replacement components are pre-filled, and under normal operating conditions, additional fluid is not required for the life of the vehicle. The fluid required for use in the clutch hydraulic system is brake fluid conforming to DOT 3 specifications and J1703 standards. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 1263 Clutch Fluid: Fluid Type Specifications HYDRAULIC - FLUID CAUTION: Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system. NOTE: The clutch hydraulic system and replacement components are pre-filled, and under normal operating conditions, additional fluid is not required for the life of the vehicle. The fluid required for use in the clutch hydraulic system is brake fluid conforming to DOT 3 specifications and J1703 standards. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .............................................. 6.2 Liters ( 6.5 qts ) Note: Includes heater and recover/reserve bottle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1268 Coolant: Fluid Type Specifications The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. IMPORTANT: The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1269 Coolant: Service Precautions CAUTION: Failure to use proper antifreeze could cause radiator plugging and engine overheating. Do not mix antifreeze brands or use plain water or alcohol base antifreeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1270 Coolant: Description and Operation DESCRIPTION CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. Do not mix coolant types. If coolant other than Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent is added, the mixed coolant will have a reduced service schedule. The use of aluminum cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent ethylene glycol based coolant with corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37 °C (-35 °F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. Mixing of coolants other than specified (nonHOAT), will reduce the 5 year/100,000 mile corrosion protection. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1271 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37 °C (-34 °F) to -46 °C (-50 °F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer (Special Tool 8286) will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant-corrosion protection will be severely reduced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1276 Differential Fluid - A/T: Fluid Type Specifications 41TE AUTOMATIC TRANSAXLE Recommended Fluid Type ........................................................................................................................................................ Mopar ATF +4, Type 9602 Recommended Sealer ......................................................................................................................... .......................................... Mopar RTV (MS-GF41) NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Page 1277 Differential Fluid - A/T: Testing and Inspection 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Page 1278 Differential Fluid - A/T: Service and Repair 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Specifications > Capacity Specifications Differential Fluid - M/T: Capacity Specifications Type ................................................................................................................................. Mopar ATF +4 (Automatic Transmission Fluid - Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. NOTE: The 41TE Automatic and T350 Manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1283 Differential Fluid - M/T: Fluid Type Specifications Type ................................................................................................................................. Mopar ATF +4 (Automatic Transmission Fluid - Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. NOTE: The 41TE Automatic and T350 Manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1288 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1289 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1290 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1291 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1292 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transaxle Estimated Service Fill .......................................................................................................................... ............................................................. 4.0 Qt (3.8L) Overhaul Fill Capacity w/Torque Converter Empty .......................................................................................................................................... 8.6 Qt (8.1L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1295 Fluid - A/T: Fluid Type Specifications 41TE AUTOMATIC TRANSAXLE Automatic Transmission Fluid .................................................................................................................................................... Mopar ATF +4, Type 9602 NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1296 Fluid - A/T: Service Precautions CAUTION: Using a transmission fluid other than ATF +4 may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than ATF +4 will result in more frequent fluid and filter changes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing Fluid - A/T: Testing and Inspection Diagnosis and Testing Effects of Incorrect Fluid Level DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation and varnish build up which interferes with valve and clutch operation. Foaming also causes fluid expansion, which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Fluid Contamination DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: * adding incorrect fluid * failure to clean dipstick and fill tube when checking level * engine coolant entering the fluid * internal failure that generates debris * overheat that generates sludge (fluid breakdown) * failure to reverse flush cooler and lines after repair * failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Causes of Burnt Fluid DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 1299 Fluid - A/T: Testing and Inspection Fluid Level and Condition Check 41TE - Automatic Transaxle FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF +4 (Automatic Transmission Fluid Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82 °C (180 °F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 180). The fluid level should be within the COLD region of the dipstick at 27 °C (80 °F) fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 1300 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 181). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF +4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF +4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check Procedure for Checking Fluid Level Check the fluid level while the transmission is at normal operating temperature. this occurs after at least 15 miles (25 km) of driving. At normal operating temperature, which is approximately 180 °F (82 °C), the fluid cannot be held comfortably between the fingers. To check the fluid level properly, the following procedure must be used: 1. The vehicle must be on level ground. 2. The engine should be running at curb idle speed for a minimum of 60 seconds. 3. Fully apply parking brake. 4. Place the gear selector momentarily in each gear position ending with the lever in P (PARK). 5. Remove the dipstick, wipe it clean and reinsert it until seated. 6. Remove the dipstick again and note the fluid level on both sides. The fluid level should be in the crosshatch area at normal operating temperatures. If the fluid is low, add as required into the dipstick tube. DO NOT OVERFILL. Note: If it is necessary to check the transmission below the operating temperature, the fluid level should be between the two cold (lower) holes on the dipstick with the fluid approximately 80 °F (27 °C) (room temperature). If the fluid level is correctly established at room temperature, it should be between the HOT (upper) reference holes when the transmission reaches 180 °F (82 °C). Remember, it is best to check the level at the normal operating temperature. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1303 Fluid - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 182). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 in. lbs.). 5. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1304 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications FLUID CAPACITY NV T350 Manual Transaxle ...................................................................................................................................................... 2.4 - 2.7Liters (2.5 - 2.8 Qt) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1309 Fluid - M/T: Fluid Type Specifications Type ..................................................................................................................................................... ..................................... Mopar ATF +4 (Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Standard Procedure - Fluid Drain and Fill Fluid - M/T: Service and Repair Standard Procedure - Fluid Drain and Fill T350 - Manual Transmission STANDARD PROCEDURE - FLUID DRAIN AND FILL NOTE: The fluid required in this transaxle is Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). T350 - Manual Transmission All T350 transaxles are equipped with a fill plug. The fill plug is located on the left side of the transaxle differential area (Fig. 92). The fluid level should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when checking). T350 - Manual Transmission All T350 transaxles are equipped with a drain plug. The drain plug is located on the lower right side of the transaxle differential housing (Fig. 93). Tighten drain plug to 28 Nm (250 inch lbs.). Fill transaxle to capacity. Refer to chart shown. Wipe the outside of the transaxle if any lubricant spills. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Standard Procedure - Fluid Drain and Fill > Page 1312 Fluid - M/T: Service and Repair Standard Procedure - Fluid Level Check Fluid Level Check Check the fluid level by removing the fill plug. The fluid level should be between the bottom of the fill hole and a point not more than 3/16" (4.76 mm) below the bottom of the hole. Add fluid, if necessary, to maintain the proper level. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ...................................................... 4.3Liters (4.5 Qt) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1317 Engine Oil: Fluid Type Specifications Engine Oil Viscosity Below 100°F (38°C) ............................................................................................................................. ................................................... 5W-30 (Preferred) Above 0°F (-18°C) ............................................................................................................................... .................................................................... 10W-30 The proper SAE viscosity grade of engine oil should be selected based on the following recommendation and be within the operating temperature shown in the engine oil viscosity chart. Synthetic Engine Oils There are a growing number of engine oils being promoted as either synthetic or semi-synthetic. If you choose to use such a product, use only those oils that meet the American Petroleum Institute (API) and (SAE) viscosity standard. Follow the service schedule that describes your driving type. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1318 Engine Oil: Service Precautions American Petroleum Institute (API) Engine Oil Identification Symbol For best performance and maximum protection for all engines under all types of operation, select only engine oils that meet American Petroleum Institute (API) certification and SAE viscosity standards. This symbol on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1319 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CHECK 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. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (Fig. 114) and observe oil level. Add oil only when the level is at or below the ADD mark (Fig. 115). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1320 Engine Oil: Service and Repair STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Remove oil fill cap (Fig. 114). 3. Raise vehicle on hoist. 4. Place a suitable oil collecting container under oil pan drain plug (Fig. 116). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1321 5. Remove oil pan drain plug and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Remove oil filter. 7. Install and tighten oil pan drain plug to 27 Nm (20 ft. lbs.). 8. Install new oil filter. 9. Lower vehicle and fill crankcase with specified type and amount of engine oil. 10. Install oil fill cap. 11. Start engine and inspect for leaks. 12. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1326 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1327 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1328 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications The power steering pump has a dipstick. Fluid should be maintained at the proper level indicated on the dipstick. CAUTION: The power steering fluid should be checked on a level surface with the engine off. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1331 Power Steering Fluid: Fluid Type Specifications Automatic Transmission Fluid Type Automatic Transmission Fluid Type Mopar ATF+4, Automatic Transmission Fluid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1332 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602) in the power steering system. Do not overfill the system. The power steering fluid level can be viewed on the dipstick attached to the filler cap. Before opening the power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on the dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should register between the ADD and FULL markings on the dipstick. The optimum level is at the FULL line. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refer to the refrigerant A/C Specification tag for system capacity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1337 Refrigerant: Fluid Type Specifications A/C Refrigerant Type A/C Refrigerant Type R-134a Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1338 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1339 http://www.macsw.org/ Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1340 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > R-134A Refrigerant Refrigerant: Service and Repair R-134A Refrigerant STANDARD PROCEDURE - R-134A REFRIGERANT This vehicle uses a refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge and/or poor performance. Never add any other type of refrigerant to a system designed to use R-134a refrigerant. System failure will occur. The high pressure service port is located on the filter/drier. The low pressure service port is located on the suction line near the strut tower. Fig. 31 Refrigerant Recovery/Recycling Station - Typical When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > R-134A Refrigerant > Page 1343 Fig. 32 Manifold Gauge Set - Typical A manifold gauge set might be required with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the oil that is specified on the under hood label and/or the compressor housing The use of R 134a will have a positive environmental impact due to its zero ozone depletion and low global warming impact. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > R-134A Refrigerant > Page 1344 Refrigerant: Service and Repair Refrigerant - Recovery STANDARD PROCEDURE - REFRIGERANT RECOVERY WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. See the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES Total System ........................................................................................................................................ ......................................................... 180 ml (6.1 oz.) Filter-Drier ............................................................................................................................................ ............................................................ 30 ml (1 oz.) Condenser ........................................................................................................................................... ............................................................... 30 ml (1 oz.) Evaporator ........................................................................................................................................... .............................................................. 59 ml (2 oz.) Refrigerant Lines ................................................................................................................................. ........................................................... 44 ml (1.5 oz.) Compressor ......................................................................................................................................... ..................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1349 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil ..................................................................................................................................... .............................................................. ND-8 PAG PAG - PolyAlkylene Glycol Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1350 Refrigerant Oil: Service Precautions CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1351 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic based PolyAlkylene Glycol (PAG), wax-free lubricant Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The 10S15 and 10S17 compressors used in this vehicle is designed to use an ND-8 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level Refrigerant Oil: Service and Repair Refrigerant Oil Level STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK 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. Refrigerant Oil Capacities When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R-134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level > Page 1354 Refrigerant Oil: Service and Repair Servicing Refrigerant Oil Level STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Recovery/recycling equipment will measure the lubricant being removed. This is the amount of lubricant to be added back to the system. If a new compressor is being installed, drain lubricant from the old compressor, measure the amount drained and discard old lubricant. Drain the lubricant from the new compressor into a clean container. Return the amount of lubricant measured from the old compressor, plus the amount reclaimed from the system back into the new compressor. 1. Discharge refrigerant system using recovery/recycling equipment if charge is present. 2. Disconnect refrigerant lines from A/C compressor. Cap the open lines to prevent moisture from entering system. 3. Remove compressor from vehicle. 4. From suction port on top of compressor, drain lubricant from compressor. 5. Add system capacity minus the capacity of components that have not been replaced. Add lubricant through the suction port on compressor. This is not to exceed 180 ml (6.10 oz.) in total. 6. Install compressor and connect refrigerant lines. Then evacuate and charge refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Washer Fluid > Component Information > Specifications Washer Fluid: Specifications Fill the reservoir with windshield washer solvent. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise. 2. Refer to one of the following depending on whether the master cylinder is a non-ABS unit Step a or an ABS unit Step b: a. Attach four Master Cylinder Bleed Tubes, Special Tool 8358-1, to the four ports of the master cylinder and tighten each in place. The bleed tubes for the ports pertaining to the rear brakes are made to attach to the proportioning valves screwed into the master cylinder. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. b. Attach Master Cylinder Bleed Tube, Special Tool 8358-1, to the primary port of the master cylinder and tighten in place. Attach Master Cylinder Bleed Tube, Special Tool 8358-2, to the secondary port of the master cylinder and tighten in place. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. 3. Fill the brake fluid reservoir with fresh Mopars brake fluid, or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel as a pushrod, press the pistons inward slowly applying brake pressure, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled out of the tubes and master cylinder bore. 5. Remove the bleed tubes from the master cylinder and plug the outlet ports. 6. Install the fill cap on the reservoir. 7. Remove the master cylinder from the vise. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1362 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. - Use only Mopar brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not pump the brake pedal at any time while a bleeder screw is open. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1363 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRBIII scan tool to the Data Link Connector. The connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRBIII, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRBIII. 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 YOURSELF AND 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. 5. Using the DRBIII, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1364 Brake Bleeding: Service and Repair Standard Procedure - Manual Bleeding MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least 1 full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1365 Brake Bleeding: Service and Repair Standard Procedure - Pressure Bleeding PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Following the same wheel circuit sequence as prescribed for manual bleeding. 1. Attach Adapter, Special Tool 6921, to the master cylinder reservoir. 2. Attach Bleeder Tank, Special Tool C-3496-B, or an equivalent, to the adapter on the master cylinder. 3. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 4-8 ounces of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 1369 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-11-2 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1374 8w-11-3 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1375 Circuit Breakers Circuit Breakers Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1376 Circuit Breaker: Diagrams Circuit Breakers - LHD Circuit Breakers - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1381 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1382 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1383 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1384 Fuse: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1385 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block Fuse: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 1388 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 1389 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 1390 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 1391 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 1392 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1397 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1398 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1399 Fuses (Fuse Block) - RHD Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1400 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1401 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1402 Fuse Block: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1403 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1406 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1407 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block Fuse Block: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 1410 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 1411 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 1412 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 1413 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 1414 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Fuse Block Fuse Block: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Fuse Block > Page 1417 Fuse Block: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Fuse Block: Service and Repair Fuse Block FUSE BLOCK WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The Fuse Block is serviced with the instrument panel wire harness. If service is required to the fuse block, the entire instrument panel harness must be replaced. REMOVAL 1. Remove the instrument panel. 2. With the instrument panel removed, disassemble the instrument panel enough to gain access to all screws and connectors. 3. Remove instrument panel wire harness with fuse block. INSTALLATION 1. Install the instrument panel wire harness to the instrument panel. 2. Install all items removed from the instrument panel to gain access to the wire harness. 3. Install the instrument panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block > Page 1420 Fuse Block: Service and Repair Power Distribution Center POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 1425 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 1426 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 1427 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 1428 Relay Box: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 1429 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 1432 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 1433 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 1434 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 1435 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 1436 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Power Distribution Center Relay Box: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Power Distribution Center > Page 1439 Relay Box: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Page 1440 Relay Box: Service and Repair POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Malfunction Indicator Light ................................................................................................................... ............................................................... LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Application and ID > Page 1445 Malfunction Indicator Lamp: Description and Operation Refer to the Instrument Cluster for more information. The PCM supplies the malfunction indicator (check engine) lamp ON/OFF signal to the instrument panel through the PCI Bus. The PCI Bus is a communications port. Various modules use the PCI Bus to exchange information. The Check Engine lamp comes ON each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Malfunction Indicator Lamp (MIL) stays ON continuously when the PCM has entered a Limp-In mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM compensates for the failure of certain components that send incorrect signals. The PCM substitutes for the incorrect signals with inputs from other sensors. If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the MIL. At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger the MIL (Check Engine Lamp) refer to the On-Board Diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Application and ID Oil Change Reminder Lamp: Application and ID This vehicle did not have an Oil Change Reminder Light. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information Vehicle Lifting: Technician Safety Information STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1454 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1455 Vehicle Lifting: Vehicle Damage Warnings STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1456 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation Tires: Description and Operation DESCRIPTION - TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Fig. 1 Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires will have a speed rating letter after the aspect ratio number. For example, the letter "S" indicates that the tire is speed rated up to 112 mph (180 km/h). The speed rating is not always printed on the tire sidewall. Q -up to 100 mph (160 km/h) - S -up to 112 mph (180 km/h) - T -up to 118 mph (190 km/h) - U -up to 124 mph (200 km/h) - H -up to 130 mph (210 km/h) - V -up to 149 mph (240 km/h) - Z -more than 149 mph (240 km/h) (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the sidewall. TIRE CHAINS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Page 1460 Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. DESCRIPTION - RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 km/h (50 mph) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Antilock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. DESCRIPTION - REPLACEMENT TIRES WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. DESCRIPTION - SPARE TIRE (TEMPORARY) The compact temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators Tires: Testing and Inspection Tread Wear Indicators DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 inch), the tread wear indicators will appear as a 13 mm (1/2 inch) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 1463 Tires: Testing and Inspection Tread Wear Patterns DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Fig. 2 Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 1464 Tires: Testing and Inspection Vehicle Lead Diagnosis and Correction DIAGNOSIS AND TESTING - VEHICLE LEAD DIAGNOSIS AND CORRECTION Use the following chart to diagnose a vehicle that has a complaint of a drift or lead condition. The use of this chart will help to determine if the lead condition is the result of a bad tire or is caused by the wheel alignment. VEHICLE LEAD DIAGNOSIS AND CORRECTION PROCEDURE *NOTE: VERIFY THAT LEAD IS NOT RELATED TO STEERING WHEEL NOT CENTERED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning CLEANING - TIRES Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil based solvent or a wire brush for cleaning. Tire Inflation Pressures STANDARD PROCEDURE - TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle (usually on the rear face of the driver's door). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Fig. 4 Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1467 Fig. 5 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks. Tire Pressure For High Speed Operation STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION Daimler Chrysler Corporation advocates driving at safe speeds within posted speed limits. Speed capacity of a tire is a function of the tire speed rating, inflation pressure and vehicle axle weight. Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. Vehicles loaded to maximum capacity should not be driven at continuous speeds over 120 km/h (75 mph). Never exceed the maximum speed capacity of the tire. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1468 Tires: Removal and Replacement STANDARD PROCEDURE - TIRE LEAK REPAIRING Fig. 7 For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area. The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the 5 wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 1473 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1474 Wheels: Specifications WHEEL SPECIFICATIONS Wheel Mounting (Lug) Nut Hex Size ................................................................................................... .................................................................. 19 mm Wheel Mounting Stud Size ................................... ...................................................................................................................................... M12 x 1.5 mm Wheel Mounting (Lug) Nut Torque .................................................................................................................................................. 135 Nm (100 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1475 Wheels: Description and Operation DESCRIPTION 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 lock-on wheel covers use large nose wheel nuts. The wheel nuts are externally threaded so that the wheel covers can be attached to the wheel nuts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1476 Wheels: Testing and Inspection DIAGNOSIS AND TESTING - WHEEL INSPECTION Inspect wheels for: Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The 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. WARNING: REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1477 Wheels: Service and Repair CLEANING WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar Wheel Treatment or Mopar Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Bearing Retainer Plate Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Rear To Knuckle Retaining Nut .................................................................................................................... ............................................ 217 Nm (160 ft. lbs.) Wheel Mounting Nuts .......................................................................................................................................................... 109-150 Nm (80-110 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair REMOVAL 1. Raise the vehicle. CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. 2. Unthread and remove the 5 nuts attaching the wheel and wheel cover to the vehicle. 3. Remove the wheel cover using care not to let the tire and wheel assembly fall off the vehicle. INSTALLATION CAUTION: Installing the wheel mounting nuts without having good metal-to-mental contact between the back of the wheel and the hub mounted brake disc or drum could cause the wheel to bind and eventually cause loosening of the wheel mounting nuts. CAUTION: Never use oil or grease on wheel studs or wheel mounting nuts. 1. With the tire and wheel assembly positioned on the wheel studs without the wheel mounting nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover on the hub mounted studs. 2. Install and lightly tighten the wheel mounting nuts in the proper sequence. 3. Lower the vehicle. 4. Progressively tighten the 5 wheel mounting nuts in the proper sequence until tightened to half of the specified torque. Finally, tighten the wheel mounting nuts in the proper sequence to 135 Nm (100 ft. lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Driveshaft Hub Nut .............................................................................................................................. ............................................ 244 Nm (180 ft. lbs.) Wheel Mounting Nuts ............................................ ........................................................................................................................... 135 Nm (100 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut Hex Size ................................................................................................................................................... 135 Nm (100 ft. lbs.) For Tightening Sequence refer to Wheels and Tires, Service and Repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front WHEEL MOUNTING STUDS - FRONT REMOVAL Use the following procedure to remove and install one of five studs on one wheel hub. 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle. 4. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side) or bottom (left side) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide abutment (on the knuckle) and rotor. 5. Hang the caliper out of the way using a wire hanger or cord. Do not support the caliper by letting it hang by the hydraulic hose. 6. Remove any retainer clips from the wheel mounting studs. Remove the brake rotor from the front hub. CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 7. Install a wheel mounting nut on the wheel mounting stud being removed from the hub far enough so the threads on the stud are even with end of lug nut. Rotate the hub so the stud requiring removal is aligned with notch cast into front of the steering knuckle. Install Remover, Special Tool C-4150A, on hub flange and wheel stud . 8. Tighten the remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1493 remover from the hub. Remove the nut from the stud, then remove the stud from the flange. INSTALLATION Use the following procedure to remove and install one of five studs on one wheel hub. Fig. 62 1. Install the wheel mounting stud in the flange of hub from the rear side. Install several washers and a wheel mounting nut on the stud. The wheel mounting nut must be installed with the flat side of the wheel mounting nut against the washers to eliminate binding. 2. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the flange of the hub. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers from the stud. 3. Install the brake rotor on the hub. 4. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 5. Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle . Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the tire and wheel assembly. Install the wheel mounting nuts and tighten them to a torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1494 Wheel Fastener: Service and Repair Rear WHEEL MOUNTING STUDS - REAR REMOVAL CAUTION: DO NOT hammer studs 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. 1. Remove the hub and bearing from the vehicle. CAUTION: Take care to keep hub and bearing assembly from falling during stud removal. Damage to the hub and bearing could result. 2. Position the hub and bearing assembly under a hydraulic press ram, supported by a 21 mm deep well impact socket under the stud to be replaced. 3. Press the stud out of the hub flange and into the socket well. 4. Remove the hub and bearing assembly from the press. 5. Remove the stud from the socket. INSTALLATION CAUTION: DO NOT hammer studs into the hub flange. If a stud is installed in such a manner, damage to the hub and bearing assembly may occur leading to premature bearing failure. 1. Install wheel stud into stud hole in hub and bearing assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1495 2. Position the hub and bearing assembly face down with stud pointing down into the well of the 21 mm socket. The hydraulic press ram must line up with the stud. 3. Press the stud into the hub flange until it bottoms. 4. Remove the hub and bearing assembly from the press. 5. Install the hub and bearing on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Technician Safety Information Jump Starting: Technician Safety Information WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Technician Safety Information > Page 1500 Jump Starting: Vehicle Damage Warnings CAUTION: - When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. - If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1501 Jump Starting: Service and Repair STANDAD PROCEDURE - JUMP STARTING WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary - Frozen battery. - Yellow or bright color test indicator, if equipped. - Low battery fluid level. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn OFF all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn OFF all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. Fig. 6 Jumper Cable Clamp Connections 5. On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 6). 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 minutes), before cranking again. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1502 Disconnect Cable Clamps As Follows: Disconnect BLACK cable clamp from engine ground on disabled vehicle. - When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal - Disconnect RED cable clamp from battery positive terminal on disabled vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information Towing Information: Technician Safety Information STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1507 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1508 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1509 Towing Information: Vehicle Damage Warnings STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1510 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1511 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information Vehicle Lifting: Technician Safety Information STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1516 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1517 Vehicle Lifting: Vehicle Damage Warnings STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1518 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25 percent Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1524 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRB III. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Bearing: > 09-007-04 > Mar > 04 > Engine - Irregular Snapping Sound Camshaft Bearing: Customer Interest Engine - Irregular Snapping Sound NUMBER: 09-007-04 GROUP: Engine DATE: March 2, 2004 SUBJECT: Irregular Engine Snapping Sound OVERVIEW: This bulletin involves chamfering the bore radius on cam bearing caps through L5 and R2 through R5. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2003 - 2004 (PL) Neon 2001 - 2004 (PT) PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 2003 - 2004 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 2.0L, 2.4L DOHC or 2.4L Turbo engine (sales code ECC, EDZ, ED1, EDV, ED2 or EDT). SYMPTOM/CONDITION: The sound may be noticed when the engine is idling in park between idle rpm and 1400 rpm at normal operating temperature. The sound is on the upper end of the engine (cylinder head) towards the front of the engine or passenger side (right side). The sound is irregular, not periodic or harmonious. The frequency of the sound will increase with RPM. The sound is more of a higher pitch snapping noise not a low metallic knock. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the technician determines that the sound is from the upper end of the engine (cylinder head) towards the front of the engine or passenger side (right side), perform the Repair Procedure. REPAIR PROCEDURE: 1. Remove the cylinder head cover (Refer to information available in TechCONNECT 9 ENGINE/CYLINDER HEAD COVER - Removal) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Bearing: > 09-007-04 > Mar > 04 > Engine - Irregular Snapping Sound > Page 1534 2. Remove L2 cam bearing cap (Fig. 1). NOTE: Do not remove the # L1/R1 or L6 cam bearing caps, or loosen the fasteners. NOTE: Only remove one cam bearing cap at a time. 3. Lightly chamfer the two bore radius edges with a small hand file, creating a 45° chamfer 1.0 to 1.5 mm in width along the edge of each bore radius (Fig. 2). CAUTION: Be careful not to scratch bore surface of cam bearing cap. Chamfer both bore radius. 4. Clean part to remove any aluminum filings prior to reinstalling. 5. Reinstall L2 cam bearing cap by loosely assembling fasteners. Prior to and during the torquing of each fastener, twist the cam bearing cap by hand in a clockwise direction, as viewed from the top of the engine. Torque M6 fasteners to 12 N.m (105 in. lbs.) while maintaining a clockwise twisting force on the cam bearing cap. 6. Repeat steps 2 through 4 for cam bearing caps L3, L4, L51 R2, R3, R4, R5 and R6. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Bearing: > 09-007-04 > Mar > 04 > Engine - Irregular Snapping Sound > Page 1535 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > 09-007-04 > Mar > 04 > Engine - Irregular Snapping Sound Camshaft Bearing: All Technical Service Bulletins Engine - Irregular Snapping Sound NUMBER: 09-007-04 GROUP: Engine DATE: March 2, 2004 SUBJECT: Irregular Engine Snapping Sound OVERVIEW: This bulletin involves chamfering the bore radius on cam bearing caps through L5 and R2 through R5. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2003 - 2004 (PL) Neon 2001 - 2004 (PT) PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 2003 - 2004 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 2.0L, 2.4L DOHC or 2.4L Turbo engine (sales code ECC, EDZ, ED1, EDV, ED2 or EDT). SYMPTOM/CONDITION: The sound may be noticed when the engine is idling in park between idle rpm and 1400 rpm at normal operating temperature. The sound is on the upper end of the engine (cylinder head) towards the front of the engine or passenger side (right side). The sound is irregular, not periodic or harmonious. The frequency of the sound will increase with RPM. The sound is more of a higher pitch snapping noise not a low metallic knock. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the technician determines that the sound is from the upper end of the engine (cylinder head) towards the front of the engine or passenger side (right side), perform the Repair Procedure. REPAIR PROCEDURE: 1. Remove the cylinder head cover (Refer to information available in TechCONNECT 9 ENGINE/CYLINDER HEAD COVER - Removal) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > 09-007-04 > Mar > 04 > Engine - Irregular Snapping Sound > Page 1541 2. Remove L2 cam bearing cap (Fig. 1). NOTE: Do not remove the # L1/R1 or L6 cam bearing caps, or loosen the fasteners. NOTE: Only remove one cam bearing cap at a time. 3. Lightly chamfer the two bore radius edges with a small hand file, creating a 45° chamfer 1.0 to 1.5 mm in width along the edge of each bore radius (Fig. 2). CAUTION: Be careful not to scratch bore surface of cam bearing cap. Chamfer both bore radius. 4. Clean part to remove any aluminum filings prior to reinstalling. 5. Reinstall L2 cam bearing cap by loosely assembling fasteners. Prior to and during the torquing of each fastener, twist the cam bearing cap by hand in a clockwise direction, as viewed from the top of the engine. Torque M6 fasteners to 12 N.m (105 in. lbs.) while maintaining a clockwise twisting force on the cam bearing cap. 6. Repeat steps 2 through 4 for cam bearing caps L3, L4, L51 R2, R3, R4, R5 and R6. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > 09-007-04 > Mar > 04 > Engine - Irregular Snapping Sound > Page 1542 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 1543 Camshaft Bearing: Specifications Bearing Clearance- Diametrical 0.0021 - 0.0037 inch Bearing Clearance (Max. Allowable) 0.0047 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 85 ft.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal REMOVAL - CAMSHAFT SPROCKET 1. Remove timing belt. 2. Hold camshaft sprocket with Special Tools C-4687 and modified Adaptor C-4687-1 (Fig. 170), while removing attaching bolt. NOTE: For Special Tool Identification, Refer to SPECIAL TOOLS. 3. Remove camshaft sprocket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1549 Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation CAMSHAFT SPROCKET 1. Install camshaft sprocket. While holding sprockets with Special Tools C-4687 and modified Adaptor C-4687-1, tighten attaching bolt to 115 Nm (85 ft. lbs.). 2. Install timing belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Journal Diameter No.1 1.619-1.6199 in. No.2 1.634 - 1.635 inch No.3 1.650 - 1.651 inch No.4 1.666 - 1.668 inch No.5 1.682 - 1.6829 inch Bearing Clearance- Diametrical 0.0021 - 0.0037 inch Bearing Clearance (Max. Allowable) 0.0047 inch End Play 0.002 - 0.015 inch Lift (Zero Lash) Standard Engine Intake 0.283 inch Exhaust 0.277 inch Lift (Zero Lash)-High Output R/T Engine Intake 0.335 inch Exhaust 0.315 inch Exhaust Valve Timing" Standard Engine Closes (ATDC) 5.4° *All readings in crankshaft degrees, at 0.5 mm (0.019 inch) of valve lift. Opens (BBDC) 43.7° Duration 229.1° Exhaust Valve Timing" High Output R/T Engine Closes (ATDC) 2.8° *All readings in crankshaft degrees, at 0.5 mm (0.019 inch) of valve lift. Opens (BBDC) 45.7° Duration 228.6° Intake Valve Timing* Standard Engine Closes (ABDC) 41.1° *All readings in crankshaft degrees, at 0.5 mm (0.019 inch) of valve lift. Opens (ATDC) 13.9° Duration 207.2° Valve Overlap None Intake Valve Timing* High Output R/T Engine Closes (ABDC) 45.8° *All readings in crankshaft degrees, at 0.5 mm (0.019 inch) of valve lift. Opens (ATDC) 12.6° Duration 213.2° Valve Overlap None Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1553 Camshaft: Description and Operation DESCRIPTION The camshaft is made of nodular iron with five bearing journal surfaces and three cam lobes per cylinder. Provision for a cam position sensor is provided on the rear of the camshaft. The camshaft position sensor bolts to the rear of the cylinder head and also controls camshaft thrust. A hydrodynamic oil seal is used for oil control at the front of the camshaft. OPERATION The camshaft is driven by the crankshaft via drive sprockets and belt. The camshaft has precisely machined lobes to provide accurate valve timing and Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1554 Camshaft: Testing and Inspection CAMSHAFT END-PLAY 1. Measure camshaft end play using the following procedure: a. Mount dial indicator C-3339 or equivalent, to a stationary point on cylinder head (Fig. 23). b. Using a suitable tool, move camshaft to rear-ward limits of travel. c. Zero the dial indicator. d. Move camshaft forward to limits of travel and read dial indicator. e. End play travel: 0.13 - 0.33 mm (0.005 - 0.013 inch). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1555 Camshaft: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. 2. Disconnect positive battery cable. Remove the battery. 3. Disconnect the IAT sensor electrical connector. 4. Disconnect the following: ^ Air intake duct at throttle body ^ Throttle cables ^ TPS and JAC connectors ^ Make-up air hose at air cleaner housing 5. Remove the air cleaner housing assembly. 6. Remove the battery tray. 7. Remove the front timing belt cover, timing belt, and tensioner. 8. Remove the camshaft sprocket and rear timing belt cover. 9. Remove the cylinder head cover. 10. Mark rocker arm shaft assemblies so that they are installed in their original positions. 11. Remove rocker arm and shafts assembly. 12. Drain cooling system below heater hose level. 13. Disconnect the ECT sensor electrical connector. 14. Disconnect hoses from heater supply and return tubes. 15. Remove heater tube support bracket bolts at rear of cylinder head. 16. Remove PDC attaching screws and reposition for camshaft removal clearance. 17. Remove camshaft sensor and camshaft target magnet. 18. Carefully remove camshaft from the rear of cylinder head. Reposition heater tubes and PDC for camshaft clearance (Fig. 24). 19. Remove the camshaft seal. CLEANING Clean camshaft with a suitable solvent. INSPECTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1556 1. Inspect camshaft bearing journals for damage and binding (Fig. 25). If journals are binding, check the cylinder head for damage. Also check cylinder head oil holes for clogging. 2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the rocker arms. 3. Measure the lobe actual wear (unworn area wear zone = actual wear) (Fig. 25) and replace camshaft if out of limit. Standard value is 0.0254 mm (0.001 inch), wear limit is 0.254 mm (0.010 inch). INSTALLATION 1. Lubricate the camshaft journals with oil. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1557 2. Carefully install the camshaft into the cylinder head. Reposition the PDC and heater tubes for clearance (Fig. 24). 3. Install camshaft target magnet into the end of the camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.). 4. Install camshaft position sensor. 5. Measure camshaft end-play. NOTE: Camshaft must be installed before installation of the camshaft seal. 6. Install camshaft seal. 7. Install rear timing belt cover. 8. Install the camshaft sprocket on the camshaft. CAUTION: DO NOT use an impact wrench (or any other air operated tool) for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. ONLY use a hand wrench while holding camshaft sprocket with Special Tool. 9. Install camshaft sprocket retaining bolt. While holding sprocket with Special Tools C-4687 and modified Adaptor C-4687-1, tighten attaching bolt to 115 Nm (85 ft. lbs.). 10. Install timing belt and tensioner. 11. Install front timing belt cover. 12. Install rocker arm assemblies in correct order as removed. Tighten the rocker arm assemblies in sequence shown in (Fig. 26) to 28 Nm (250 in. lbs.). 13. Install the cylinder head cover. 14. Install ignition coil and spark plug cables. Tighten ignition coil fasteners to 12 Nm (105 in. lbs.). 15. Install the heater tube bracket attaching bolt. 16. Connect the heater hoses to the heater tubes. 17. Connect the ECT electrical connector. 18. Install the PDC attaching screws. 19. Install the battery tray. 20. Install the air cleaner housing assembly. 21. Connect the following: ^ Air intake duct at throttle body ^ Throttle cables ^ TPS and JAC connectors ^ Make-up air hose at air cleaner housing 22. Connect the IAT sensor. 23. Install battery. Connect positive battery cable. 24. Connect negative battery cable. 25. Refill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1558 26. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB 1116 scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 "For information regarding this component please refer to Rocker Arm Testing and Inspection" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1562 Lifter / Lash Adjuster: Service and Repair "For information regarding this component please refer to Rocker Arm service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft-Bolts 250 in.lbs. Rocker Arm Shaft Rocker Arm Shaft Diameter 0.7861 - 0.7868 inch Rocker Arm Shaft Retainers Intake-Width 1.1193 - 1.1217 inch Exhaust-Width 1 & 5 1.1477 - 1.1516 inch Exhaust-Width 2,3, and 4 1.5906 - 1.5945 inch Rocker Arm/Hydraulic Lash Adjuster Rocker Arm Inside Diameter 0.787 - 0.788 inch Rocker Arm Shaft Clearance 0.0006 - 0.0021 inch Body Diameter 0.9035 - 0.9040 inch Plunger Travel Minimum (Dry) 0.087 inch Dry Lash-Intake 0.039 inch Dry Lash-Exhaust 0.055 inch Rocker Arm Ratio 1.4 to 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1566 Rocker Arm Assembly: Testing and Inspection HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS 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 (integral to the head gasket) in 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. e 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. ^ Remove suspected lash adjusters, and replace as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1567 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove cylinder head cover. 2. Identify the rocker arm shaft assemblies before removal. 3. Loosen the attaching fasteners. Remove rocker arm shaft assemblies from cylinder head. 4. Identify the rocker arms spacers and retainers for reassembly. Disassemble the rocker arm assemblies by removing the attaching bolts from the shaft (Fig. 37). 5. Slide the rocker arms and spacers off the shaft. Keep the spacers and rocker arms in the same location for reassembly. INSPECTION 1. Inspect the rocker arm for scoring, wear on the roller or damage to the rocker arm (Fig. 38). Replace as necessary. 2. Check the location where the rocker arms mount to the shafts for wear or damage. Replace if damaged or worn. 3. The rocker arm shaft is hollow and is used as a lubrication oil duct. Check oil holes for clogging with small wire, clean as required. INSTALLATION CAUTION: Set crankshaft to 3 notches before TDC before installing rocker arm shafts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1568 1. Lubricate the rocker arms and spacers. Install onto shafts in their original position (Fig. 37). 2. Install rocker arm/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 depressed. If there is excessive plunger travel. Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the assembly. Hydraulic lash adjuster and rocker arm are serviced as an assembly Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1569 3. Install rocker arm and shaft assemblies with NOTCH in the rocker arm shafts pointing up and toward the timing belt side of the engine (Fig. 39). Install the retainers in their original positions on the exhaust and intake shafts (Fig. 37). CAUTION: When installing the intake rocker arm shaft assembly be sure that the plastic spacers do not interfere with the spark plug tubes. If the spacers do interfere rotate until they are at the proper angle. To avoid damaging the spark plug tubes, do not attempt rotating the spacers by forcing down the shaft assembly. 4. Tighten bolts to 28 Nm (250 in. lbs.) in sequence shown in (Fig. 40). 5. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance 0.001 - 0.0023 inch Side Clearance 0.005 - 0.015 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1574 Connecting Rod Bearing: Service and Repair CONNECTING ROD AND BEARING - FITTING 1. Measure connecting rod bearing clearance using Plastigage (Fig. 54). CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. NOTE: The rod bearing bolts should not be reused. 2. Before installing NEW bolts, lubricate the threads with clean engine oil. 3. Install each bolt finger tight than 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 (Fig. 55). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Connecting Rod: Specifications Bearing Clearance 0.001 - 0.0023 in Wear Limit 0.003 in Bore Diameter - Piston Pin 0.8252 - 0.8260 in Bore Diameter - Crankshaft end 2.0075 - 2.0081 in Side Clearance 0.005 - 0.015 in Side Clearance Wear Limit 0.016 in Weight - Total (Less Bearing) 1.20 lb (US) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 1579 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts ..................................................................................................................................................... 27 Nm (20 ft. lbs.) + 1/4 turn Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1580 Connecting Rod: Description and Operation "For information regarding this component please refer to Piston description and Operation" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1581 Connecting Rod: Service and Repair CONNECTING ROD AND BEARING - FITTING 1. Measure connecting rod bearing clearance using Plastigage (Fig. 54). CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. NOTE: The rod bearing bolts should not be reused. 2. Before installing NEW bolts, lubricate the threads with clean engine oil. 3. Install each bolt finger tight than 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 (Fig. 55). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Removal Crankshaft Gear/Sprocket: Service and Repair Removal REMOVAL - CRANKSHAFT SPROCKET 1. Remove timing belt 2. Remove the crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 171). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Removal > Page 1586 Crankshaft Gear/Sprocket: Service and Repair Installation CRANKSHAFT SPROCKET NOTE: Make sure the word "front" on the sprocket is facing outward. CAUTION: Use of Special Tool 6792 is required to install the crankshaft sprocket to the proper depth. Failure to use this tool will cause improper timing belt tracking. 1. Install the crankshaft sprocket (Fig. 172) using Special Tool 6792. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications Crankshaft Main Bearing: Specifications Main Bearing Diametrical Clearance 0.0008 - 0.0024 in Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 1591 Crankshaft Main Bearing: Specifications Torque Specifications 1. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. 2. Tighten bolts 1 - 10 to 81 Nm (60 ft. lbs.). 3. Tighten bolts 11 - 20, with baffle studs in positions 12, 13 and 16, to 34 Nm (25 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1592 Crankshaft Main Bearing: Service and Repair Main Bearing Fitting The crankshaft is supported in five main bearings. All upper and lower bearing shells in the crankcase have oil grooves. The number three lower main thrust bearing is plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 66). 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 (Fig. 66). 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: 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch). Never install an undersize bearing that will reduce clearance below specifications. MAIN BEARING INSTALLATION 1. Install the main bearing shells with the lubrication groove in the cylinder block (Fig. 67). 2. Make certain oil holes in block line up with oil holes in bearings. Bearing tabs must seat in the block tab slots. CAUTION: Do not get oil on the bedplate mating surface. It will may effect the sealer ability to seal the bedplate to cylinder block. 3. Oil the bearings and journals and install crankshaft. CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. Ensure that both cylinder block and bedplate surfaces are clean. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1593 4. Apply 1.5 to 2.0 mm (0.059 to 0.078 inch) bead of anaerobic sealer Mopar Bed Plate Sealant to cylinder block as shown in (Fig. 68). 5. Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. 6. Position the main bearing/bedplate onto the engine block. 7. Before installing bolts, lubricate the threads with clean engine oil, wipe off any excess oil. 8. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. 9. To ensure correct thrust bearing alignment, perform the following steps: e Step 1: Rotate crankshaft until number 4 piston is at TDC. ^ Step 2: Move crankshaft rearward to limits of travel. ^ Step 3: Then, move crankshaft forward to limits of travel. ^ Step 4: Wedge an appropriate tool between the rear of the cylinder block (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in it's furthest forward position. ^ Step 5: Install and tighten bolts (1-10) in sequence shown in (Fig. 69) to 41 Nm (30 ft. lbs.). ^ Step 6: Remove wedge tool used to hold crankshaft. 10. Tighten bolts (1-10) again to 41 Nm (30 ft. lbs.) + 1/4 turn in sequence shown in (Fig. 69). 11. Install main bearing bedplate to engine block bolts (11-20), and torque each bolt to 28 Nm (20 ft. lbs.) in sequence shown in (Fig. 69). 12. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Connecting Rod Journal Diameter 1.8894 - 1.8900 ft Main Bearing Journal Diameter 2.0469 - 2.0475 in Journal Out of Round 0.0001 in Journal Taper 0.0001 in End Play 0.0035 - 0.0094 in End Play Wear Limit 0.015 in Main Bearing Diametrical Clearance 0.0008 - 0.0024 in Crankshaft Main Bearing Cap/Bedplate M8 Bolts 25 ft.lb Crankshaft Main Bearing Cap/Bedplate M11 Bolts 60 ft.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1597 Crankshaft: Description and Operation DESCRIPTION The crankshaft is made of nodular cast iron and includes five main bearing journals and four connecting rod journals (Fig. 56). The number three journal is the location for the thrust bearing. The mains and connecting rod journals have undercut fillet radiuses that are rolled for added strength. To optimize bearing loading, eight counterweights are used. OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures CRANKSHAFT END PLAY 1. Mount a dial indicator to front of engine, locating probe on nose of the crankshaft (Fig. 57). 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front of its travel and read the dial indicator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1600 Crankshaft: Removal and Replacement REMOVAL 1. Remove engine assembly. 2. Separate transaxle from engine. 3. Remove drive plate/flexplate. 4. Remove crankshaft rear oil seal. 5. Mount engine on a suitable repair stand. 6. Remove crankshaft vibration damper. 7. Remove engine mount bracket and front timing belt cover. 8. Remove the timing belt. 9. Remove the timing belt tensioner. 10. Remove camshaft sprocket and rear timing belt cover. 11. Remove crankshaft sprocket. 12. Remove lower torque strut/air conditioning compressor mounting bracket from engine (Fig. 58). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1601 13. Remove oil filter and adapter (Fig. 59). 14. Remove oil pan. 15. Remove oil pump pick-up tube. 16. Remove oil pump. 17. Remove crankshaft position sensor (Fig. 59). 18. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. 19. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1602 20. Remove all main bearing cap and bedplate bolts from the engine block (Fig. 60). 21. 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. 22. Bedplate should be removed evenly from the cylinder block dowel pins. 23. Lift out crankshaft from cylinder block. Be sure not to damage the main bearings or journals when removing the crankshaft. CRANKSHAFT MAIN BEARINGS LOCATION 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 (Fig. 61). NOTE: The upper and lower main Bearing shells are Not interchangeable. The lower shells have a revised tab to prevent improper installation. INSPECTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1603 The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 62). 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 No. 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, it is important that the final paper or cloth polish be in the same direction as normal rotation in the engine. Upper and lower No. 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 61). 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. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1604 1. Install the upper main bearing shells with the lubrication groove in the cylinder block. Install O-ring into recess in the block (Fig. 63). 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 in cylinder block. 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 Bed Plate Sealant to cylinder block as shown in (Fig. 64). 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 oil threads with clean engine oil, wipe off any excess oil. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1605 7. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block (Fig. 65). 8. Install main bearing bedplate to engine block bolts (1-10) and torque each bolt to 81 Nm (60 ft. lbs.) in sequence shown in (Fig. 65). 9. Install main bearing bedplate to engine block bolts (11-20), with baffle studs in positions 12, 13 and 16 and torque each bolt to 34 Nm (25 ft. lbs.) in sequence shown in (Fig. 65). 10. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 in. lbs.). 11. Check crankshaft end play. 12. Install connecting rod bearings and caps. Install new connecting rod bolts and tighten to 27 Nm (20 ft. lbs.) plus 1/4 turn. 13. Install oil pump and crankshaft front oil seal. 14. Install oil pick-up tube and oil pan. 15. Install oil filter adapter and oil filter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1606 16. Install lower torque strut/air conditioning compressor mounting bracket to engine (Fig. 58). 17. Install timing belt rear cover and camshaft sprocket. 18. Install the crankshaft sprocket. 19. Install the timing belt tensioner. 20. Install the timing belt. 21. Install front timing belt cover and engine mount bracket. 22. Remove engine from repair stand and position on Special Tools 6135 and 6710 Engine Dolly and Cradle. Install safety straps around the engine to cradle and tighten and lock them into position. 23. Install the crankshaft rear oil seal. 24. Install the flex plate. 25. Install the transaxle to engine. 26. Install the engine assembly. 27. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB 1116 scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 ENGINE BLOCK HEATER DESCRIPTION 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 (Fig. 7). The engine block heater is available as an optional accessory. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord and connector behind the radiator grille. CAUTION: The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become damaged. OPERATION The block heater element is submerged in the cooling system's coolant. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the engine coolant. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1610 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER TESTING 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1611 Engine Block Heater: Service and Repair REMOVAL 1. Drain the cooling system. 2. Detach power cord plug from heater (Fig. 7). 3. Loosen screw in center of heater. Remove heater assembly (Fig. 7). INSTALLATION 1. Thoroughly clean core hole and heater seat. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1612 2. Insert heater assembly with element loop positioned upward (Fig. 7). 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Connect power cord to block heater (Fig. 7). 5. Fill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Damper Bolt 100 ft.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1616 Harmonic Balancer - Crankshaft Pulley: Service and Repair VIBRATION DAMPER REMOVAL 1. Raise vehicle on a hoist and remove right inner splash shield. 2. Remove accessory drive belts. 3. Remove crankshaft vibration damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A (Fig. 93). INSTALLATION 1. Install crankshaft vibration damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792 (Fig. 94). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1617 2. Install vibration damper bolt. Using Special Tool 6847 and a torque wrench, tighten bolt to 136 Nm (100 ft. lbs.) (Fig. 95). 3. Install accessory drive belts. 4. Install the right inner splash shield and lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter 3.4432 - 3.4439 in Clearance at 0.42 in from bottom of skirt 0.0008 - 0.0020 in Weight 11.29 - 11.60 oz (US) Land Clearance Diametrical 0.0299 - 0.0312 in Piston Length 2.197 inch Piston Ring Groove Depth Number 1 0.157 - 0.156 in Number 2 0.176 - 0.184 in Number 3 0.151 - 0.163 in Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1621 Piston: Description and Operation PISTON & CONNECTING ROD DESCRIPTION NOTE: The engine DOES NOT have provisions 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. The pistons are made of a cast aluminum alloy The pistons have pressed-in pins attached to forged powdered metal connecting rods. The pistons pin is offset 1 mm (0.0394 inch) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. Hex head cap screws are used to provide alignment and durability in the assembly. The pistons and connecting rods are serviced as an assembly. OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures CYLINDER BORE AND PISTON - FITTING Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin about 14 mm (9/16 inch.) from the bottom of the skirt as shown in (Fig. 81). Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown in (Fig. 80). Correct piston to bore clearance must be established in order to assure quiet and economical operation. NOTE: Pistons and cylinder bores should be measured at normal room temperature, 70° F (21° C). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1624 Piston: Removal and Replacement REMOVAL 1. Remove the cylinder head. 2. Remove the oil pan. 3. 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 (Fig. 82). CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. 4. Using a permanent ink marker or scribe tool mark the cylinder number on the side of the rod and cap (Fig. 83) for identification. 5. Pistons will have a stamping in the approximate location shown in (Fig. 82). 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. 6. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 7. Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1625 8. To protect crankshaft journal and fractured rod surfaces, install Special Tool 8189, connecting rod guides onto connecting rod (Fig. 84). Carefully push each piston and rod assembly out of cylinder bore. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur. 9. Remove Special Tool 8189, connecting rod guides and re-install bearing cap on the mating rod. NOTE: Piston and rods are serviced as an assembly. 10. Remove piston rings. INSTALLATION 1. Install piston rings on piston. 2. Before installing pistons and connecting rod assemblies into the bore, ensure the compression ring gaps are staggered, and neither is in line with the oil ring rail gap. 3. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps are located as shown in (Fig. 91). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1626 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 85). Be sure position of rings does not change during this operation. 5. The weight stamp designation L or H will be in the front half of the piston should face toward the front of the engine (Fig. 82). 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil. 7. Position upper bearing half and install Special Tool 8189, connecting rod guides onto connecting rod (Fig. 84). 8. Insert rod and piston assembly into cylinder bore and carefully guide rod over the crankshaft journal. 9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 10. Remove Special Tool 8189, connecting rod guides. 11. Install connecting rod lower bearing half and cap. Install New bolts and tighten to 27 Nm (20 ft. lbs.) plus 1/4 turn. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1627 12. Install the cylinder head. 13. Install the oil pan. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance in Piston 0.0003 - 0.0006 inch Clearance in Connecting Rod Interference Diameter 0.8268 - 0.8269 inch End Play None Length 2.943 - 2.963 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Top Compression Ring 0.009 - 0.020 in Wear Limit 0.031 in Ring Gap Second Compression Ring 0.019 - 0.031 in Wear Limit 0.039 in Ring Gap Oil Control Steel Rails 0.009 - 0.026 in Wear Limit 0.039 in Ring Clearance Compression Rings 0.0010 - 0.0026 in Wear Limit 0.004 in Ring Clearance Oil Control Ring 0.0002 - 0.0070 in Ring Width Compression Rings 0.046 - 0.047 in Ring Width Oil Control Rings 0.1124 - 0.1184 in Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting Piston Ring: Service and Repair Piston Ring Fitting PISTON RING FITTING 1. 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 positioned below normal ring travel in the cylinder bore. Check gap with feeler gauge (Fig. 86). 2. Check piston ring to groove side clearance (Fig. 87). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1636 Piston Ring: Service and Repair Piston Ring - Removal and Installation REMOVAL 1. Using a suitable ring expander, remove upper and intermediate piston rings (Fig. 88). 2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 3. Clean ring grooves of any carbon deposits. INSTALLATION NOTE: The identification mark on face of upper and intermediate piston rings must point toward top of piston. Install rings with manufacturers identification mark facing up, to the top of the piston (Fig. 89). CAUTION: Install piston rings in the following order: ^ Oil ring expander. ^ Upper oil ring side rail. ^ Lower oil ring side rail. ^ No. 2 Intermediate piston ring. ^ No. 1 Upper piston ring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1637 1. Install oil ring expander (Fig. 89). 2. Install upper side rail first and then the lower side rail. Install the side rails by placing one end between the piston ring groove and the oil ring 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 (Fig. 90). 3. Install No. 2 piston ring and then No. 1 piston ring (Fig. 89). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1638 4. Position piston ring end gaps as shown in (Fig. 91). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1646 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft-Bolts 250 in.lbs. Rocker Arm Shaft Rocker Arm Shaft Diameter 0.7861 - 0.7868 inch Rocker Arm Shaft Retainers Intake-Width 1.1193 - 1.1217 inch Exhaust-Width 1 & 5 1.1477 - 1.1516 inch Exhaust-Width 2,3, and 4 1.5906 - 1.5945 inch Rocker Arm/Hydraulic Lash Adjuster Rocker Arm Inside Diameter 0.787 - 0.788 inch Rocker Arm Shaft Clearance 0.0006 - 0.0021 inch Body Diameter 0.9035 - 0.9040 inch Plunger Travel Minimum (Dry) 0.087 inch Dry Lash-Intake 0.039 inch Dry Lash-Exhaust 0.055 inch Rocker Arm Ratio 1.4 to 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1650 Rocker Arm Assembly: Testing and Inspection HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS 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 (integral to the head gasket) in 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. e 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. ^ Remove suspected lash adjusters, and replace as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1651 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove cylinder head cover. 2. Identify the rocker arm shaft assemblies before removal. 3. Loosen the attaching fasteners. Remove rocker arm shaft assemblies from cylinder head. 4. Identify the rocker arms spacers and retainers for reassembly. Disassemble the rocker arm assemblies by removing the attaching bolts from the shaft (Fig. 37). 5. Slide the rocker arms and spacers off the shaft. Keep the spacers and rocker arms in the same location for reassembly. INSPECTION 1. Inspect the rocker arm for scoring, wear on the roller or damage to the rocker arm (Fig. 38). Replace as necessary. 2. Check the location where the rocker arms mount to the shafts for wear or damage. Replace if damaged or worn. 3. The rocker arm shaft is hollow and is used as a lubrication oil duct. Check oil holes for clogging with small wire, clean as required. INSTALLATION CAUTION: Set crankshaft to 3 notches before TDC before installing rocker arm shafts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1652 1. Lubricate the rocker arms and spacers. Install onto shafts in their original position (Fig. 37). 2. Install rocker arm/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 depressed. If there is excessive plunger travel. Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the assembly. Hydraulic lash adjuster and rocker arm are serviced as an assembly Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1653 3. Install rocker arm and shaft assemblies with NOTCH in the rocker arm shafts pointing up and toward the timing belt side of the engine (Fig. 39). Install the retainers in their original positions on the exhaust and intake shafts (Fig. 37). CAUTION: When installing the intake rocker arm shaft assembly be sure that the plastic spacers do not interfere with the spark plug tubes. If the spacers do interfere rotate until they are at the proper angle. To avoid damaging the spark plug tubes, do not attempt rotating the spacers by forcing down the shaft assembly. 4. Tighten bolts to 28 Nm (250 in. lbs.) in sequence shown in (Fig. 40). 5. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1657 Valve Cover: Service and Repair CYLINDER HEAD COVER REMOVAL 1. Disconnect make-up air (Fig. 27) and PCV (Fig. 28) hoses from cylinder head cover. 2. Remove ignition coil and spark plug cables (Fig. 29). 3. Remove cylinder head cover bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1658 4. Remove cylinder head cover. CLEANING Clean cylinder head and cover mating surfaces using a suitable solvent. INSPECTION Inspect cover rails for flatness. INSTALLATION 1. Inspect gasket and seals (Fig. 30). Replace as necessary. CAUTION: Do not attempt to loosen or remove baffle plate attaching screws. The screws are self-tapping, and in the attempt to retighten, thread damage (stripping) will result. 2. Install cylinder head cover and gasket. Tighten bolts to 12 Nm (105 in. lbs.). 3. Install ignition coil and spark plug cables (Fig. 29). Tighten ignition coil fasteners to 12 Nm (105 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1659 4. Connect make-up air (Fig. 27) and PCV (Fig. 28) hoses. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Diameter I.D. 0.235 - 0.236 inch Guide Bore Diameter 0.4330 - 0.4338 inch Guide Height (spring seat to Guide Tip) 0.521 - 0.541 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle 45° Seat Diameter-Intake 1.299 inch Seat Diameter-Exhaust 1.102 inch Runout (Max.) 0.002 inch Valve Seat Width-Intake And Exhaust 0.035 - 0.051 inch Service Limit-Intake 0.079 inch Service Limit-Exhaust 0.098 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1666 Valve Seat: Description and Operation "For information regarding this component please refer to valve intake/Exhaust description and operation" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs - Standard Engine Free Length (Approx.) 1.84 inch Nominal Force (Valve Closed) 70 lbs. @ 1.57 inch Nominal Force (Valve Open) 160 lbs. @ 1.28 inch Installed Heigh 1.580 inch Valve Springs - High Output R/T Engine Free Length (Approx.) 2.13 inch Nominal Force (Valve Closed) 72 lbs. @ 1.57 inch Nominal Force (Valve Open) 167 lbs. @ 1.28 inch Installed Height 1.580 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1670 Valve Spring: Description and Operation VALVE SPRINGS OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1671 Valve Spring: Service and Repair REMOVAL - CYLINDER HEAD OFF 1. Using Special Tool C-3422-D (valve spring compressor) with Adapter 6526 compress valve spring and remove valve retaining locks. 2. Slowly release valve spring compressor. Remove valve spring retainer and valve spring. 3. Remove valve stem seal assembly. REMOVAL - CYLINDER HEAD ON 1. Remove the cylinder head cover. 2. Remove rocker arm shafts assemblies. 3. Rotate crankshaft until piston is at TDC on compression stroke. 4. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. 5. Using Special Tool MD-998772A with adapter 6779 (Fig. 46)compress valve springs and remove valve locks. 6. Remove the valve spring. 7. Remove the valve stem seal. INSPECTION When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 47). As an example; the compression length of the spring to be tested is 38.00 mm (1.496 inch). Turn table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inches.) 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. Replace springs that do not meet specifications. INSTALLATION - CYLINDER HEAD OFF 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1672 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. NOTE: On the high output R/T engine, the valve spring MUST be oriented properly when installed. The closely spaced spring coils should be positioned toward the cylinder head (spring seat) (Fig. 50). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1673 3. Position valve spring and retainer on spring seat (Fig. 49) or (Fig. 50). 4. 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. 5. Check the valve spring installed height after refacing the valve and seat (measurement B) (Fig. 48). Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 40.18 mm (1.58 inch), install a 0.762 mm (0.030 inch) spacer under the valve spring seat to bring spring height back within specification. 6. Install rocker arms and shafts. 7. 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. 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(s) to bleed down before rotating cam. INSTALLATION - CYLINDER HEAD ON 1. Install valve stem seal assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1674 NOTE: On the high output R/T engine, the valve spring MUST be oriented properly when installed. The closely spaced spring coils should be positioned toward the cylinder head (spring seat) (Fig. 50). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1675 2. Position valve spring and retainer on spring seat (Fig. 49) or (Fig. 50). 3. With air pressure applied in cylinder and piston at TDC, use Special Tool MD-998772A to compress valve springs, only enough to install the locks. Correct alignment of tool is necessary to avoid nicking valve stems. 4. Install the rocker arm shaft assemblies. 5. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valves Face Angle Intake and Exhaust 45 - 45.5° Head Diameter-Intake 1.303 - 1.313 inch Head Diameter-Exhaust 1.124 - 1.135 inch Valve Margin Intake 0.0452 - 0.0583 inch Service Limit 0.0312 inch Exhaust 0.058 - 0.071 inch Service Limit 0.0469 inch Valve Length (Overall) Intake 4.503 - 4.523 inch Exhaust 4.603 - 4.623 inch Valve Stem Tip Height Intake 1.76 - 1.80 inch Exhaust 1.71 - 1.75 inch Valve Stem Diameter Intake 0.2337 - 0.2344 inch Exhaust 0.2326 - 0.2333 inch Valve Stem to Guide Clearance Intake 0.0018 - 0.0025 inch Max. Allowable 0.003 inch Exhaust 0.0029 - 0.0037 inch Max. Allowable 0.004 inch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1679 Valve: Description and Operation INTAKE/EXHAUST VALVES & SEATS DESCRIPTION The four valves per cylinder are opened by using roller rocker arms with hydraulic lash adjusters which pivot on the rocker shafts. The valves have chrome plated valve stems. Viton rubber valve stem seals are integral with the spring seats. The valve springs, spring retainers, and locks are 3-bead design. OPERATION The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1680 Valve: Testing and Inspection CLEANING 1. Clean all valves thoroughly and discard burned, warped and cracked valves. INSPECTION VALVES 1. Measure valve stems for wear (Fig. 34) approximately 60 mm (2.36 inch) below the valve lock grooves. NOTE: Valve stems are chrome plated and should not be polished (Fig. 34). VALVE GUIDES NOTE: Replace cylinder head if stem-to-guide clearance exceeds specifications, or if guide is loose in cylinder head. 1. Measure valve stem-to-guide clearance as follows: 2. Install valve into cylinder head so it is 15 mm (0.590 inch) off the valve seat. A small piece of hose may be used to hold valve in place. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1681 3. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 35). 4. Move valve to and from the indicator. 5. Check valve guide height (Fig. 36). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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. Remove valve spring. 2. Before removing valve, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. 3. Remove valve(s) from cylinder head. INSTALLATION 1. Coat valve stems with clean engine oil. 2. Install valve in cylinder head. 3. Install valve seal. 4. Install valve springs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1684 Valve: Service and Repair Refacing Valves & Seats VALVE AND VALVE SEAT REFACING For all applicable valve and seat dimensions and angles, Refer to SPECIFICATIONS. 1. Reface valves using a suitable valve refacing machine. 2. Inspect the remaining margin after the valves are refaced (Fig. 31). Intake valves with less than 0.79 mm (0.0312 inch) margin and exhaust valves with less than 1.19 mm (0.0469 inch) margin should be replaced. 3. 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. 4. Reface valve seats using a suitable valve seat machine 5. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones or cutter. A true and complete surface must be obtained. 6. 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). 7. 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/cutter. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone/cutter. 8. When seat is properly positioned the width of intake and exhaust seats should be 0.75 - 1.25 mm (0.030 - 0.049 inch) (Fig. 32). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1685 9. Check valve tip to spring seat dimensions A after machining the valve seats or faces. Grind valve tip until within specifications. Measure from valve tip to spring seat when installed in the head (measurement A) (Fig. 33). The valve tip chamfer is needed to be reground to prevent seal damage when the valve is installed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Accessory drive belt Belt Tension Power Steering Pump & A/C Compressor Dynamic Tension Generator New 135 lbs. Used 70 lbs. A belt is considered used after 15 minutes of run-in time. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1690 Drive Belt: Description and Operation DESCRIPTION The accessory drive consist of two Poly-V type drive belts (Fig. 1). One belt drives the generator, the other drives the power steering pump and air conditioning compressor (if equipped). The power steering/ air conditioning belt is tensioned by an automatically controlled belt tensioner. The generator belt is manually tensioned using an adjusting bolt and a locking nut. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1691 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt Drive Belt: Service and Repair A/C Compressor / Power Steering Pump Belt REMOVAL POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 3). CLEANING Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1694 Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1695 1. Install the drive belt (Fig. 3) over all the pulleys except for the power steering pump pulley 2. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be installed on the power steering pulley Release spring tension onto belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1696 3. After belt is installed, inspect belt length indicator marks (Fig. 7). The indicator mark should be within the minimum belt length and maximum belt length marks. On a new belt, the indicator mark should align approximately with the nominal belt length mark. DRIVE BELT TENSION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1697 Drive Belt: Service and Repair Alternator/Generator Belt REMOVAL GENERATOR BELT 1. Remove power steering pump/air conditioning compressor drive belt. 2. Loosen generator locking nut (Fig. 4). 3. Raise vehicle on hoist. 4. Remove accessory drive belt splash shield (Fig. 5). 5. Loosen generator pivot bolt (Fig. 4). 6. Loosen generator adjusting bolt until generator belt can be removed (Fig. 4). 7. Remove generator belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1698 CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. GENERATOR BELT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1699 1. Install belt around pulleys (Fig. 3). 2. Adjust belt tension by tightening adjusting bolt (Fig. 4). Adjust belt to specification shown in DRIVE BELT TENSION CHART. 3. Check belt tension using Special Tool 8371 Belt Tension Gauge Adapter, and the DRB III using the following procedures: WARNING: DO NOT CHECK BELT TENSION WITH ENGINE RUNNING. a. Connect 8371 to the DRB III following the instructions provided with tool. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1700 b. Place end of microphone probe approximately 2.54 cm (1 inch) from belt at one of the belt center span locations shown in (Fig. 8). c. Pluck the belt a minimum of 3 times. (Use your finger or other suitable tool) d. The frequency of the belt in hertz (Hz) will display on DRB III screen. e. Adjust belt to obtain proper frequency (tension). 4. Tighten generator pivot bolt to 54 Nm (40 ft. lbs.) (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1701 5. Install accessory drive belt splash shield (Fig. 5). 6. Lower vehicle. 7. Tighten generator locking nut to 54 Nm (40 ft. lbs.) (Fig. 4). 8. Install power steering pump/air conditioning compressor drive belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1702 DRIVE BELT TENSION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1703 Drive Belt: Service and Repair Power Steering Belt REMOVAL POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 3). CLEANING Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1704 Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: ^ Excessive wear ^ Frayed cords ^ Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1705 1. Install the drive belt (Fig. 3) over all the pulleys except for the power steering pump pulley 2. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 2) until belt can be installed on the power steering pulley Release spring tension onto belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Compressor / Power Steering Pump Belt > Page 1706 3. After belt is installed, inspect belt length indicator marks (Fig. 7). The indicator mark should be within the minimum belt length and maximum belt length marks. On a new belt, the indicator mark should align approximately with the nominal belt length mark. DRIVE BELT TENSION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Automatic belt tensioner pulley-bolt 20 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1710 Drive Belt Tensioner: Description and Operation DESCRIPTION The automatic belt tensioner (Fig. 9) maintains proper tension on the power steering and air conditioning belt. The tensioner is serviced with the engine mount bracket assembly. The tensioner pulley can be serviced separately. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1711 Drive Belt Tensioner: Service and Repair REMOVAL NOTE: Slight axial movement of the tensioner arm is normal. Tensioner arm should move freely and maintain 50 - 70 lbs. tension on belt. 1. Remove engine mount bracket assembly. 2. Remove the tensioner pulley mounting bolt. 3. Remove the pulley. INSTALLATION 1. Install tensioner pulley, dust shield, and bolt. Tighten bolt to 27 Nm (20 ft. lbs.). 2. Install engine mount bracket assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Specifications Engine Torque Strut: Specifications Engine Torque Strut Bracket To Engine-Bolts 45 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Service and Repair > Torque Strut Engine Torque Strut: Service and Repair Torque Strut TORQUE STRUT REMOVAL UPPER TORQUE STRUT 1. Remove bolts attaching strut to shock tower bracket and engine mount bracket (Fig. 106). 2. Remove the upper torque strut. LOWER TORQUE STRUT 1. Raise vehicle on hoist. 2. Remove accessory drive belt splash shield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Service and Repair > Torque Strut > Page 1718 3. Remove pencil strut (Fig. 105). 4. Remove bolts attaching lower strut to crossmember and strut bracket (Fig. 106). 5. Remove lower torque strut. INSTALLATION UPPER TORQUE STRUT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Service and Repair > Torque Strut > Page 1719 1. Position the upper torque strut into mounting locations (Fig. 106). 2. Install the mounting bolts and perform the torque strut adjustment procedure. LOWER TORQUE STRUT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Service and Repair > Torque Strut > Page 1720 1. Position lower torque strut into mounting locations (Fig. 106). 2. Install mounting bolts and perform torque strut adjustment procedure. 3. Install pencil strut (Fig. 105). 4. Install accessory drive belt splash shield and lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Service and Repair > Torque Strut > Page 1721 Engine Torque Strut: Service and Repair Adjustments ENGINE TORQUE STRUT ADJUSTMENT The upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine mount loading. Whenever a torque strut bolt(s) is loosened, this procedure must be performed. 1. Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket. 2. The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the transmission bell housing (Fig. 107). NOTE: The floor jack must be positioned as shown in (Fig. 107) to prevent minimal upward lifting of the engine. 3. With the engine supported, remove the upper and lower torque strut attachment bolt(s) at shock tower bracket and suspension crossmember (Fig. 106). Verify that the torque struts are free to move within the shock tower bracket and crossmember. Reinstall the torque strut bolt(s), but do not Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Service and Repair > Torque Strut > Page 1722 tighten. 4. Carefully apply upward force, allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching stud on the engine mount bracket (point "A") and the center of the hole for the washer hose clip on the shock tower bracket (point "B") is 119 mm (4.70 inch) (Fig. 108). 5. With the engine held at the proper position, tighten both the upper and lower torque strut bolts to 118 Nm (87 ft. lbs.) (Fig. 106). 6. Remove the floor jack. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed 4 psi (at normal operating temperature) If oil pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 25-80 psi Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1727 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE Check oil pressure using a gauge at oil pressure switch location. 1. Remove the oil pressure switch. 2. Install oil pressure test gauge, Special Tool C-3292 with Adapter 8406. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM. 3. Warm engine to normal operating temperature. 4. Monitor gauge readings at idle and 3000 rpm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain-Plug 20 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ...................................................... 4.3Liters (4.5 Qt) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1735 Engine Oil: Fluid Type Specifications Engine Oil Viscosity Below 100°F (38°C) ............................................................................................................................. ................................................... 5W-30 (Preferred) Above 0°F (-18°C) ............................................................................................................................... .................................................................... 10W-30 The proper SAE viscosity grade of engine oil should be selected based on the following recommendation and be within the operating temperature shown in the engine oil viscosity chart. Synthetic Engine Oils There are a growing number of engine oils being promoted as either synthetic or semi-synthetic. If you choose to use such a product, use only those oils that meet the American Petroleum Institute (API) and (SAE) viscosity standard. Follow the service schedule that describes your driving type. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1736 Engine Oil: Service Precautions American Petroleum Institute (API) Engine Oil Identification Symbol For best performance and maximum protection for all engines under all types of operation, select only engine oils that meet American Petroleum Institute (API) certification and SAE viscosity standards. This symbol on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1737 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CHECK 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. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (Fig. 114) and observe oil level. Add oil only when the level is at or below the ADD mark (Fig. 115). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1738 Engine Oil: Service and Repair STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Remove oil fill cap (Fig. 114). 3. Raise vehicle on hoist. 4. Place a suitable oil collecting container under oil pan drain plug (Fig. 116). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1739 5. Remove oil pan drain plug and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Remove oil filter. 7. Install and tighten oil pan drain plug to 27 Nm (20 ft. lbs.). 8. Install new oil filter. 9. Lower vehicle and fill crankcase with specified type and amount of engine oil. 10. Install oil fill cap. 11. Start engine and inspect for leaks. 12. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 15 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1743 Oil Filter: Service and Repair OIL FILTER REMOVAL CAUTION: When servicing the oil filter (Fig. 116), avoid deforming the filter. Use an appropriate oil filter removing tool. Position filter wrench strap close the seam at the base of the filter. The oil filter seam that joins the can to the base, is reinforced by the base plate. 1. Turn filter counterclockwise to remove (Fig. 116). INSTALLATION 1. Clean and check the filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. 2. Lubricate new filter gasket. 3. Screw filter on until gasket contacts base (Fig. 116). Tighten to 21 Nm (15 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adaptor 60 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 1747 Oil Filter Adapter: Service and Repair OIL FILTER ADAPTER REMOVAL REMOVE 1. Remove the oil filter. 2. Remove assembly by unscrewing adaptor fitting (Fig. 135). 3. Remove O-ring seal. INSTALLATION 1. Position O-ring in the groove on adapter. 2. Align roll pin into engine block and tighten assembly to 80 Nm (60 ft. lbs.) (Fig. 135). 3. Install oil filter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan-Bolts 105 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1751 Oil Pan: Service and Repair OIL PAN REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Drain engine oil and remove oil filter. 4. Remove oil filter adaptor from engine block (Fig. 117). 5. Remove structural collar. 6. Remove lateral bending brace attaching bolts (Fig. 118). 7. Remove lateral bending brace (Fig. 118). 8. Remove transaxle dust cover (Fig. 118). 9. Remove oil pan bolts. 10. Remove oil pan. INSTALLATION 1. Clean oil pan and all sealing surfaces. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1752 2. Apply Mopar Silicone Rubber Adhesive Sealant at the oil pump to engine block parting line (Fig. 119). 3. Position a new oil pan gasket onto pan. 4. Install oil pan and tighten screws to 12 Nm (105 in. lbs.). 5. Install transaxle dust cover (Fig. 118). 6. Install lateral bending brace (Fig. 118). 7. Install structural collar. 8. Install oil filter adaptor. 9. Install oil filter. 10. Lower vehicle and fill engine crankcase with proper oil to correct level. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation OIL PRESSURE SENSOR/ SWITCH DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 120). The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). OPERATION The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig of the switch's "Closed" circuit pressure point. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Description and Operation > Page 1756 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle. 2. Position oil collecting container under pressure switch location. 3. Disconnect oil pressure switch electrical connector and remove switch (Fig. 121). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 121). 2. Lower vehicle. 3. Start engine and allow to run a minimum of 2 minutes. 4. Shut engine off and check engine oil level. Adjust level as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1760 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Low Oil Pressure Indicator .................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID > Page 1764 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The low oil pressure indicator 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. Fig.2 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 (Fig. 2). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Plate-Bolts 105 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil Pump Pick-up Tube-Bolt 250 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed 4 psi (at normal operating temperature) If oil pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 25-80 psi Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1775 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE Check oil pressure using a gauge at oil pressure switch location. 1. Remove the oil pressure switch. 2. Install oil pressure test gauge, Special Tool C-3292 with Adapter 8406. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM. 3. Warm engine to normal operating temperature. 4. Monitor gauge readings at idle and 3000 rpm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications 1. Tighten lower intake manifold bolts in sequence shown. Torque to 2. Tighten upper intake manifold fasteners in sequence shown. Torque to 12 Nm (105 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 1780 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts .............................................................................................................................................................. 23 Nm (200 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1781 Intake Manifold: Description and Operation INTAKE MANIFOLD - HIGH OUTPUT DESCRIPTION The intake manifold is a two piece cast aluminum design. The lower manifold section houses an electronic controlled manifold tuning valve for increased engine performance. OPERATION The intake manifold meters and delivers air to the combustion chambers. This air allows the fuel delivered by the fuel injectors to ignite; producing power. The Manifold Tuning Valve (MTV) allows additional flow volumes under certain engine operating conditions for increase engine performance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1782 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKS 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 engine RPM'S change, the area of the suspected leak has been found. 4. Repair as required. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1783 Intake Manifold: Service and Repair REMOVAL - HIGH OUTPUT ENGINE 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. Perform fuel system pressure release procedure before attempting any repairs. WARNING: WRAP SHOP TOWELS AROUND FUEL HOSE TO CATCH ANY GASOLINE SPILLAGE 3. Disconnect fuel supply line quick connect at the fuel tube assembly. 4. Disconnect fuel injector connector and harness from injectors and fuel rail. 5. Disconnect PCV hose from manifold (Fig. 144). 6. Remove the inlet air duct from intake manifold to throttle body Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1784 7. Remove bolt attaching lower intake manifold to support bracket (Fig. 143). 8. Remove engine oil dipstick from housing. 9. Disconnect electrical connectors from MAP sensor and MTV actuator (Fig. 144). 10. Remove bolts attaching intake manifold to cylinder head. 11. Move manifold forward for access to wiring connections (Fig. 146). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1785 12. Disconnect the knock sensor (Fig. 145). 13. Disconnect brake booster hose (Fig. 146). 14. Remove intake manifold. INSTALLATION - HIGH OUTPUT ENGINE 1. Clean manifold sealing surfaces. 2. If separated, install lower to upper manifold gasket and tighten bolt in sequence shown in (Fig. 147) to 12 Nm (105 in. lbs.). 3. Position new manifold gasket on cylinder head mounting surface, piloting on the 2 attaching studs. 4. Loosely position manifold in engine compartment. 5. Insert engine wiring harness between middle intake runners. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1786 6. Connect the knock sensor (Fig. 145). 7. Connect brake booster hose (Fig. 146). 8. Position manifold to cylinder head and install fasteners. Tighten fasteners in sequence shown in (Fig. 148) to 12 Nm (105 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1787 9. Install bolt securing lower manifold to bracket (Fig. 143). Tighten bolt to 28 Nm (250 in. lbs.). 10. Connect MAP sensor and MTV actuator electrical connection (Fig. 144). 11. Install engine oil dipstick 12. Connect inlet air duct to manifold and throttle body 13. Connect PCV hose to manifold (Fig. 144). 14. Connect fuel injector connectors and harness to fuel rail. 15. Connect fuel supply line to fuel rail. 16. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Low Oil Pressure Indicator .................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID > Page 1792 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The low oil pressure indicator 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. Fig.2 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 (Fig. 2). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair Camshaft Oil Seal: Service and Repair CAMSHAFT OIL SEAL REMOVAL 1. Disconnect and isolate negative battery cable. 2. Remove front timing belt cover. 3. Remove the timing belt and tensioner assembly. CAUTION: Do Not Rotate the camshaft or crankshaft when timing belt is removed damage to the engine may occur. 4. Hold camshaft sprocket with Special Tools C-4687 and modified C-4687-1 as shown in (Fig. 21), while removing attaching bolt. 5. Remove sprocket from camshaft. 6. Remove the rear timing belt cover. 7. Remove camshaft seal by carefully using a suitable pry tool. 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. 8. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper, if necessary. INSTALLATION 1. Install camshaft seal flush with cylinder head using Special Tool MD998306 (Fig. 22). 2. Install the rear timing belt cover. 3. Install the camshaft sprocket on the camshaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Page 1797 CAUTION: DO NOT use an impact wrench (or any other air operated tool) for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. ONLY use a hand wrench while holding camshaft sprocket with Special Tool. 4. Install camshaft sprocket retaining bolt. Hold camshaft sprocket with Special Tools C-4687 and modified C-4687-1 (Fig. 21) and tighten bolt to 115 Nm (85 ft. lbs.). 5. Install timing belt and tensioner assembly. 6. Install front timing belt cover. 7. Connect negative battery cable. 8. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB III scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Remove the transaxle. 2. Remove the flex plate. 3. Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver (Fig. 75) 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1801 1. Place Special Tool 6926-1 on crankshaft. This is a pilot tool with a magnetic base (Fig. 76). 2. Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal (Fig. 76). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1802 3. Drive the seal into the block using Special Tool 6926-2 and handle C-4171 (Fig. 77) until the tool bottoms out against the block (Fig. 78). 4. Install the flex plate. 5. Install the transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Remove the accessory drive belts. 2. Remove the crankshaft vibration damper. 3. Remove the timing belt. 4. Remove the crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 70). 5. Remove the crankshaft sprocket key from crankshaft (Fig. 71). CAUTION: Do not nick shaft seal surface or seal bore. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1806 6. Using Special Tool 6771, remove front crankshaft oil seal (Fig. 72). Do not damage the seal contact area on the crankshaft. INSTALLATION 1. Position seal into opening with seal spring towards the inside of engine. Using Special Tool 6780-1 (Fig. 73), install seal until flush with cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1807 2. Install the crankshaft sprocket key (Fig. 71). 3. Install the crankshaft sprocket (Fig. 74) using Special Tool 6792. NOTE: Make sure the word "front" on the sprocket is facing outward. CAUTION: Use of Special Tool 6792 is required to install the crankshaft sprocket to the proper depth. Failure to use this tool will cause improper timing belt tracking. 4. Install the timing belt. 5. Install crankshaft vibration damper. 6. Install accessory drive belts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair VALVE STEM SEALS REMOVAL 1. Remove valve spring. 2. Remove valve stem seals by using a valve stem seal tool (Fig. 44). INSTALLATION 1. The valve stem seal/valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not remove garter spring around the seal at the top of the valve stem seal (Fig. 45). 2. Install valve spring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation OIL PRESSURE SENSOR/ SWITCH DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 120). The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). OPERATION The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig of the switch's "Closed" circuit pressure point. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Page 1815 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle. 2. Position oil collecting container under pressure switch location. 3. Disconnect oil pressure switch electrical connector and remove switch (Fig. 121). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 121). 2. Lower vehicle. 3. Start engine and allow to run a minimum of 2 minutes. 4. Shut engine off and check engine oil level. Adjust level as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1819 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 85 ft.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal REMOVAL - CAMSHAFT SPROCKET 1. Remove timing belt. 2. Hold camshaft sprocket with Special Tools C-4687 and modified Adaptor C-4687-1 (Fig. 170), while removing attaching bolt. NOTE: For Special Tool Identification, Refer to SPECIAL TOOLS. 3. Remove camshaft sprocket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1826 Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation CAMSHAFT SPROCKET 1. Install camshaft sprocket. While holding sprockets with Special Tools C-4687 and modified Adaptor C-4687-1, tighten attaching bolt to 115 Nm (85 ft. lbs.). 2. Install timing belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Removal Crankshaft Gear/Sprocket: Service and Repair Removal REMOVAL - CRANKSHAFT SPROCKET 1. Remove timing belt 2. Remove the crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 171). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Removal > Page 1831 Crankshaft Gear/Sprocket: Service and Repair Installation CRANKSHAFT SPROCKET NOTE: Make sure the word "front" on the sprocket is facing outward. CAUTION: Use of Special Tool 6792 is required to install the crankshaft sprocket to the proper depth. Failure to use this tool will cause improper timing belt tracking. 1. Install the crankshaft sprocket (Fig. 172) using Special Tool 6792. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications Timing Belt: Specifications Timing Belt Replacement Interval On 2000-02 Neon models, replace every 105,000 miles or 84 months in normal service, or every 105,000 miles in severe service. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation Timing Belt: Service and Repair Installation With Mechanical Tensioner TIMING BELT (WITH MECHANICAL TENSIONER) 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC (Fig. 178). 2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear timing belt cover (Fig. 179). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1837 3. Move crankshaft to 1/2 mark before TDC (Fig. 180) for belt installation. 4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket, then around the camshaft sprocket, and finally route the back side of the timing belt around the timing belt tensioner pulley 5. Move crankshaft sprocket to TDC to take up belt slack. 6. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate COUNTERCLOCKWISE. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang (Fig. 181). Using the allen wrench to prevent the top plate from moving, torque the tensioner lock nut to 30 Nm (22 ft. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued. 7. Remove allen wrench and torque wrench. NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1838 8. Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position (Fig. 183). 9. Check if the spring tang is within the tolerance window (Fig. 182). If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 6 through 8. 10. Install front timing belt cover. 11. Install spark plugs. 12. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB 1116 scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. With Hydraulic Tensioner Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1839 TIMING BELT (WITH HYDRAULIC TENSIONER) 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC (Fig. 173). 2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover (Fig. 174). 3. Move crankshaft to 1/2 mark before TDC (Fig. 175) for belt installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1840 4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket, then around the camshaft sprocket, and finally route the back side of the timing belt around the timing belt tensioner pulley 5. Move crankshaft sprocket to TDC to take up belt slack. 6. Re-set the hydraulic tensioner by placing tensioner body in a vise equipped with soft jaws (Fig. 176). Slowly compress the plunger. 7. Compress the plunger until a 1.9 mm (5/64) Allen wrench or pin can be inserted through the body and the plunger (Fig. 176). 8. Remove hydraulic tensioner from vise and install on engine. Do not tighten attaching bolts at this time. 9. Using a torque wrench on the tensioner pulley bolt, apply 28 Nm (250 in. lbs.) of torque against the timing belt. 10. With torque applied to the tensioner pulley/ timing belt, move the tensioner up against the pulley pivot bracket and tighten tensioner bolts to 31 Nm (23 ft. lbs.). (Fig. 177). 11. Pull the tensioner plunger retaining pin. Pretension is correct when the pin can be removed and installed into tensioner housing and plunger. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1841 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks (Fig. 175) and (Fig. 174). 13. Check belt tension by installing pin into tensioner housing. If pin cannot be re-installed, repeat belt tension procedure. 14. Install the front timing belt cover. 15. Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB III scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1842 Timing Belt: Service and Repair Removal With Mechanical Tensioner TIMING BELT (WITH MECHANICAL TENSIONER) 1. Remove front timing belt cover (Fig. 168). 2. Remove spark plugs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1843 CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine CLOCKWISE with the crankshaft (Fig. 183). 3. Loosen timing belt tensioner lock nut (Fig. 169). 4. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate CLOCKWISE until there is enough slack in timing belt to allow for removal (Fig. 169). 5. Remove timing belt. CAUTION: Do not rotate the camshaft once the timing belt has been removed or damage to valve components may occur. With Hydraulic Tensioner TIMING BELT (WITH HYDRAULIC TENSIONER) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1844 1. Remove front timing belt cover (Fig. 165). CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Installation > Page 1845 2. Rotate crankshaft until timing marks are aligned at both the camshaft and crankshaft (Fig. 166). 3. Loosen the timing belt tensioner fasteners (Fig. 166). CAUTION: DO NOT loosen, tighten, or remove the tensioner pivot bolt (Fig. 167). 4. Remove the timing belt from sprockets. CAUTION: Do not rotate the camshaft once the timing belt has been removed or damage to valve components may occur. 5. For timing belt tensioner pulley assembly removal Refer to TIMING BELT TENSIONER & PULLEY - REMOVAL. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Timing Belt Tensioner Assembly Bolts 250 in.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal Timing Belt Tensioner: Service and Repair Removal With Hydraulic Tensioner WITH HYDRAULIC TENSIONER 1. Remove timing belt. 2. Remove bolts attaching the tensioner pulley assembly to engine. 3. Remove tensioner pulley assembly (Fig. 184). With Mechanical Tensioner WITH MECHANICAL TENSIONER 1. Remove timing belt. 2. Remove bolts attaching the timing belt tensioner assembly to engine. 3. Remove timing belt tensioner assembly (Fig. 185). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal > Page 1851 Timing Belt Tensioner: Service and Repair Installation With Hydraulic Tensioner WITH HYDRAULIC TENSIONER 1. Position timing belt tensioner assembly to the engine. To ensure proper alignment of tensioner to engine block, temporarily install the engine mount bracket bolts into the upper holes of the timing belt tensioner. Install timing belt tensioner lower mounting bolts. Tighten lower mounting bolts to 31 Nm (23 ft. lbs.). Remove temporarily installed engine mount bracket bolts. 2. Install timing belt. With Mechanical Tensioner WITH MECHANICAL TENSIONER 1. Position timing belt tensioner assembly to the engine. To ensure proper alignment of tensioner to engine block, temporarily install the engine mount bracket bolts into the upper holes of the timing belt tensioner. Install timing belt tensioner lower mounting bolts. Tighten lower mounting bolts to 31 Nm (23 ft. lbs.). Remove temporarily installed engine mount bracket bolts. 2. Install timing belt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Belt Cover Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1855 Timing Cover: Service and Repair Timing Belt CoversREMOVAL FRONT COVER 1. Disconnect negative battery cable. 2. Remove fastener securing ground strap to engine mount bracket. 3. Remove upper torque strut. 4. Remove power steering/air conditioning compressor drive belt. 5. Raise vehicle on hoist. 6. Remove accessory drive belt splash shield. 7. Remove generator drive belt. 8. Remove crankshaft damper bolt. Remove crankshaft damper (Fig. 158). 9. Remove lower torque strut. 10. Lower vehicle. 11. Position a jack under engine. Raise jack enough to support engine weight. 12. Remove right engine mount to engine mount bracket through bolt (Fig. 159). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1856 13. Lower engine enough with jack to remove lower engine mount bracket bolt (Fig. 160). 14. Raise engine with jack to allow engine-to-body clearance for engine mount bracket removal. 15. Remove power steering pump assembly and set aside. Do Not disconnect lines from pump. 16. Remove the two remaining bolts securing engine mount bracket to engine. Remove engine mount bracket (Fig. 160). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1857 17. Remove the front timing belt cover fasteners. Remove front timing belt cover (Fig. 161). REAR COVER 1. Remove front timing belt cover. 2. Remove timing belt. 3. Remove timing belt tensioner assembly. 4. Hold camshaft sprocket with Special Tools C-4687 and modified Adaptor C-4687-1 (Fig. 162), while removing attaching bolt. NOTE: For Special Tool Identification, Refer to SPECIAL TOOLS. 5. Remove camshaft sprocket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1858 6. Remove rear cover attaching bolts (Fig. 163). 7. Remove rear cover (Fig. 163). INSTALLATION REAR COVER 1. Install rear cover and tighten bolts to 12 Nm (105 in. lbs.) (Fig. 163). 2. Install the camshaft sprocket on the camshaft. CAUTION: DO NOT use an impact wrench (or any other air operated tool) for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. ONLY use a hand wrench while holding camshaft sprocket with Special Tool. 3. Install camshaft sprocket retaining bolt. While holding sprocket with Special Tools C-4687 and modified Adaptor C-4687-1, tighten attaching bolt to 115 Nm (85 ft. lbs.). 4. Install timing belt tensioner assembly. 5. Install timing belt. 6. Install front timing belt cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1859 FRONT COVER 1. Install front cover and tighten bolts to 12 Nm (105 in. lbs.) (Fig. 161). 2. Position engine mount bracket to its mounting location. Hand start the upper two bolts of the engine mount bracket (Fig. 160). 3. Lower engine with jack. 4. Install lower engine mount bracket bolt. Tighten bolt to 61 Nm (45 ft. lbs.) (Fig. 160). 5. Raise engine with jack. 6. Tighten upper engine mount bracket bolts to 61 Nm (45 ft. lbs.) (Fig. 160). 7. Install power steering pump assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1860 8. Lower engine with jack. 9. Install right engine mount to engine mount bracket through bolt. Tighten bolt to 118 Nm (87 ft. lbs.) (Fig. 159). 10. Remove jack from under engine. 11. Raise vehicle on hoist. 12. Install lower torque strut. 13. Install crankshaft damper (Fig. 164). Install crankshaft damper bolt. Torque bolt to 136 Nm (100 ft. lbs.). 14. Install accessory drive belts. 15. Install accessory drive belt splash shield. 16. Lower vehicle. 17. Install upper torque strut. 18. Install fastener securing ground strap to engine mount bracket. 19. Connect negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE ............................................................................................................................... ......................................... 400 ± 34 kPa (58 ± 5 psi) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1865 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1866 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1867 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 AIR CLEANER ELEMENT REMOVAL 1. Remove 5 screws from air cleaner element box lid. 2. Remove lid from air cleaner box. 3. Pull air cleaner up and out of air cleaner box. INSTALLATION 1. Install air cleaner element on to throttle body and push towards the throttle body and past lip in air cleaner box bottom (Fig. 10). 2. Install lid and tighten screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1879 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1883 The electronic ignition coil pack attaches directly to the valve cover. The 2.0 Liter (122 cu. inch) in-line four cylinder engine is a single over head camshaft with hydraulic lifters and four valves per cylinder design (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE ................................................................................................................................................. ........................................................ RESISTANCE # 1, # 4 ................................................................................................................................................. ..................................................... 2970 - 8910 ohms # 2, # 3 ................................................................................................................................................. ..................................................... 2360 - 7070 ohms Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1891 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature silicone materials. All spark plug cable leads are properly identified with cylinder numbers. The inside of most the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1892 Ignition Cable: Service and Repair REMOVAL 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. Remove spark plug cable from coil first. 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. INSTALLATION 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. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair Spark Plug Tube: Service and Repair SPARK PLUG TUBE REMOVAL 1. Remove the cylinder head cover. 2. Using locking pliers, remove the tube from the cylinder head. Discard old tube. INSTALLATION 1. Clean area around spark plug with Mopar parts cleaner or equivalent. 2. Apply Mopar Stud and Bearing Mount or equivalent to a new tube approximately 1 mm (0.039 inch) from the end in a 3 mm (0.118 inch) wide area. 3. Install sealer end of tube into the cylinder head. Then carefully install the tube using a hardwood block and mallet until the tube is seated into the bottom of the bore. 4. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation Spark Plug Tube Seal - Valve Cover: Description and Operation DESCRIPTION The spark plug tube seals are located in the cylinder head cover. These seals are pressed into the cylinder head cover to seal the outside perimeter of the spark plug tubes. If these seals show signs of hardness and/or cracking, they should be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation > Page 1900 Spark Plug Tube Seal - Valve Cover: Service and Repair REMOVAL 1. Remove the cylinder head cover. 2. Using an appropriate tool, carefully remove spark plug tube seals. Care should be taken not to damage cylinder head cover sealing surfaces. INSTALLATION 1. Clean all sealing surfaces. NOTE: Position seal with the concave side facing the installation tool. 2. Install seals using Special Tool MB-998306. Only hand pressure on tool is needed to install new seals. 3. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25 percent Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1904 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRB III. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Inlet Tube to Engine Block-Bolt 105 in.lb Water Pump to Engine Block-Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1911 Water Pump: Description and Operation DESCRIPTION The water pump has a diecast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the cylinder block and is driven by the timing belt. Cylinder block to water pump sealing is provided by a rubber O-ring. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. OPERATION The water pump is the heart of the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, and radiator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1912 Water Pump: Testing and Inspection WATER PUMP DIAGNOSIS A quick flow test to determine water pump operation is check for proper heater operation. A defective pump will not circulate heated coolant through the heater hoses. An additional flow test can by performed by the following the procedures below: WARNING: DO NOT remove radiator cap if the cooling system is hot or under pressure. 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1913 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts. 3. Drain the cooling system. 4. Remove power steering pump attaching bolts and set pump and assembly aside. Power steering lines do not need to be disconnected. 5. Remove upper and lower torque isolator struts. 6. Support the engine from bottom and remove right engine mount attaching bolt. 7. Remove right engine mount bracket. 8. Remove the timing belt. 9. Remove the timing belt tensioner. 10. Remove camshaft sprocket and rear timing belt cover. 11. Remove water pump attaching screws to engine and remove pump. INSPECTION Replace water pump body assembly if it has any of these defects: 1. Cracks or damage on the body 2. Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body 3. Loose or rough turning bearing. 4. Impeller rubs either the pump body or the engine block. 5. Impeller loose or damaged. 6. Sprocket or sprocket flange loose or damaged. INSTALLATION 1. Apply Mopar Dielectric Grease to O-ring before installation. 2. Install new O-ring gasket in water pump body O-ring groove. CAUTION: Ensure O-ring gasket is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring, resulting in a coolant leak. 3. Assemble pump body to block and tighten screws to 12 Nm (105 in. lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1914 4. Rotate pump by hand to check for freedom of movement. 5. Install timing belt rear cover and camshaft sprocket. 6. Install timing belt tensioner. 7. Install the timing belt. 8. Install the engine right mount bracket. 9. Install the upper and lower torque isolator struts. 10. Fill the cooling system. 11. Install the accessory drive belts. 12. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB 1116 scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .............................................. 6.2 Liters ( 6.5 qts ) Note: Includes heater and recover/reserve bottle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1920 Coolant: Fluid Type Specifications The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. IMPORTANT: The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1921 Coolant: Service Precautions CAUTION: Failure to use proper antifreeze could cause radiator plugging and engine overheating. Do not mix antifreeze brands or use plain water or alcohol base antifreeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1922 Coolant: Description and Operation DESCRIPTION CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. Do not mix coolant types. If coolant other than Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent is added, the mixed coolant will have a reduced service schedule. The use of aluminum cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent ethylene glycol based coolant with corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37 °C (-35 °F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. Mixing of coolants other than specified (nonHOAT), will reduce the 5 year/100,000 mile corrosion protection. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1923 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37 °C (-34 °F) to -46 °C (-50 °F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer (Special Tool 8286) will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant-corrosion protection will be severely reduced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water Pump Inlet Tube to Engine Block-Bolts 105 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications > Page 1927 Coolant Line/Hose: Description and Operation WATER PUMP INLET TUBE DESCRIPTION The water pump inlet tube connects the water pump housing to the radiator lower hose and heater return hose. This plastic tube is sealed by an O-ring and held in place by fasteners to the block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Heater Supply/Return Tubes Coolant Line/Hose: Service and Repair Heater Supply/Return Tubes HEATER SUPPLY RETURN TUBES REMOVAL NOTE: It is not necessary to remove the intake manifold to replace heater supply/return tubes. 1. Disconnect negative battery cable. Disconnect positive battery cable. Remove battery. 2. Raise vehicle on hoist. 3. Drain cooling system. 4. Remove hose clamp from heater return tube located near starter. Disconnect hose from tube. 5. Lower vehicle 6. Remove air cleaner housing and throttle body to intake manifold hose. 7. Disconnect PCV vacuum hose at intake manifold. 8. Remove hose clamp from heater supply tube located near thermostat housing. Disconnect hose from tube. 9. Remove two heater hose clamps and disconnect heater hoses near battery. 10. Unclip wiring harness from heater tube assembly 11. Remove transmission dipstick tube and place an appropriate plug into hole to prevent coolant from entering transmission. 12. Remove fasteners attaching heater tube assembly to cylinder head and engine block. 13. Remove heater tube assembly. NOTE: After heater tube assembly is removed, the short hoses connecting the tubes to the thermostat housing and water pump inlet tube can be replaced at this time. INSTALLATION 1. Inspect all hoses that connect to heater tubes. Replace if necessary. 2. Position heater tube assembly near it's mounting location. 3. Connect hoses at water pump inlet tube and thermostat housing. Ensure clamps are positioned properly to seal hoses and avoid contact with engine components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Heater Supply/Return Tubes > Page 1930 4. Install fasteners attaching heater tube assembly to cylinder head and engine block. NOTE: Before installing transmission dipstick tube clean any residual coolant from around the area where plug was placed. 5. Remove plug from transmission dipstick tube mounting hole. Install transmission dipstick tube. 6. Reattach wiring harness to heater tube assembly. 7. Connect two heater hoses to heater tubes near battery. Ensure clamps are positioned properly to seal hoses and avoid contact with engine components. 8. Connect PCV vacuum hose to intake manifold. 9. Install air cleaner housing and throttle body to intake manifold hose. 10. Raise vehicle on hoist. 11. Close radiator draincock. 12. Lower vehicle 13. Install battery. Connect positive battery cable. Connect negative battery cable. 14. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Heater Supply/Return Tubes > Page 1931 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube WATER PUMP INLET TUBE REMOVAL 1. Drain the cooling system. 2. Remove the radiator upper hose to access the hose connections at the inlet tube. 3. Remove the intake manifold. CAUTION: Do not use any sharp tools to remove hoses from inlet tube. This may cause the tube to leak. 4. Remove the radiator lower hose and heater hose from the inlet tube. 5. Remove the lower intake manifold support bracket. 6. Remove the inlet tube to the block fasteners. 7. 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 Mopar Dielectric Grease and install inlet tube into the cylinder block opening. 3. Install inlet tube fasteners and tighten to 12 Nm (105 in. lbs.). 4. Install intake manifold lower support bracket fasteners and tighten to 12 Nm (105 in. lbs.). 5. Connect the radiator lower hose and heater hose to inlet tube. 6. Install the intake manifold. 7. Install the radiator upper hose. 8. Fill the cooling system. 9. Pressure test cooling system and check for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Coolant Recovery Container- Nut/Screw 35 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 1935 Coolant Reservoir: Service and Repair COOLANT RECOVERY CONTAINER REMOVAL 1. Disconnect recovery hose from water outlet connector/thermostat housing . 2. Remove container attaching fasteners. 3. Remove coolant recovery container. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 1936 1. Install coolant recovery container and tighten fasteners to 4 Nm (35 in. lbs.)). 2. Connect recovery hose to water outlet connector/thermostat housing. 3. Fill container to proper level. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Radiator Fan to Radiator- Screws 65 in.lbs. Radiator Fan Motor to Shroud- Screws 34 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1943 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1944 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1945 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1946 Radiator Fan Motor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1947 Radiator Cooling Fan Motor: Description and Operation DESCRIPTION The radiator fan is a single speed electric motor driven fan. The radiator fan assembly components includes an electric motor, a fan blade, and a support shroud that is attached to the radiator. Each component of the fan assembly can be serviced separately. Depending on Engine/Transmission combination, the vehicle may be equipped with a single fan or a dual fan. NOTE: Vehicles equipped with dual fans, each fan blade is different from the other. OPERATION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1948 Radiator fan control operation is accomplished two ways. The fan will always run when the air conditioning compressor clutch is engaged. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the Powertrain Control Module (PCM). The PCM turns on the fan through a fan relay by grounding the relay's coil. The fan relay is located in the Power Distribution Center (PDC). Refer to the label beneath the PDC cover for location of fan relay. The PCM will actuate the fan relay whenever the A/C clutch is engaged regardless of coolant temperature and vehicle speed. If the A/C clutch is not engaged, the PCM will actuate the fan relay when the coolant temperature reaches approximately 97 °C (207 °F) and turns off the fan relay when the coolant temperature drops to approximately 94 °C (201 °F). The fan relay is also turned off when the vehicle speed is above approximately 100 km/h (62 mph). If the radiator fan is inoperative or a Diagnostic Trouble Code (DTC) related to fan control has been set, Refer to the Appropriate Diagnostic Information for complete diagnostic procedures. RADIATOR FAN OPERATION CHART Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1949 Radiator Cooling Fan Motor: Service and Repair REMOVAL WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Disconnect negative cable from battery. 2. Drain cooling system below the upper radiator hose level. 3. Remove upper hose from radiator. 4. Remove fasteners that attach air cleaner housing to vehicle. Reposition air cleaner housing. 5. Raise vehicle on hoist. 6. Disconnect and remove the Powertrain Control Module (PCM) with bracket. 7. Disconnect radiator fan electrical connector. 8. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1950 9. Remove radiator upper support mounts. 10. Remove air conditioning line support bracket screw. 11. Remove radiator fan assembly screws from radiator. 12. Carefully lift radiator fan assembly up and out of lower shroud attachment clips. 13. For radiator fan assembly sub-component removal procedures, Refer to RADIATOR FAN DISASSEMBLY. DISASSEMBLY The radiator fan assembly consist of the following three components: fan, fan motor, and shroud. FAN 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. 1. Remove radiator fan assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1951 2. Remove fan hub retaining nut. 3. Remove fan from motor shaft. FAN MOTOR 1. Remove radiator fan assembly. 2. Remove fan from motor shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1952 3. Remove screw attaching the in-rush current suppressor. 4. Remove screws attaching motor to shroud . 5. Remove the fan motor. SHROUD 1. Remove radiator fan assembly. 2. Remove the FAN. 3. Remove the FAN MOTOR. ASSEMBLY FAN 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. 1. Install fan on motor shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1953 2. Install fan retaining nut and tighten to 6.2 Nm (55 in. lbs.). 3. Install radiator fan assembly. FAN MOTOR 1. Install the fan motor on shroud and tighten screws to 3.8 Nm (34 in. lbs.). 2. Install screw attaching the in-rush current suppressor and tighten to 2.6 Nm (23 in. lbs.). 3. Install the fan on motor shaft. 4. Install the radiator fan assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1954 SHROUD 1. Install the FAN MOTOR 2. Install the FAN . 3. Install the radiator fan assembly. INSTALLATION 1. Install radiator fan assembly by lowering into position on radiator. Ensure the fan assembly lower mounts are engaged properly into slots on lower radiator tank. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1955 2. Install the radiator fan assembly retaining screws and tighten to 7.5 Nm (65 in. lbs.) . 3. Install radiator upper support mounts and tighten bolts to 10 Nm (90 in. lbs.). 4. Install air conditioning line support bracket screw. 5. Raise vehicle on hoist. 6. Connect radiator fan electrical connector. 7. Install powertrain control module (PCM). 8. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1956 9. Install air cleaner housing fasteners. 10. Install radiator upper hose to radiator. Align hose and position clamp to ensure proper clearance with engine or hood. 11. Fill cooling system. 12. Connect negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1960 Radiator Fan Relays Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1961 Radiator Fan High Relay (1.6L/2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1962 Radiator Cooling Fan Motor Relay: Testing and Inspection Test 1 - 4 Test 5 SYMPTOM CHECKING RADIATOR FAN RELAY OUTPUT POSSIBLE CAUSES - Radiator fan relay operation - Ground circuit open - Radiator fan motor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1963 - Fused B+ circuit - Radiator fan relay output circuit - Radiator fan relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications Radiator Fan Blade to Motor Shaft-Nut 55 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Application and ID Coolant Temperature Sensor / Switch HVAC: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Climate Controls .................................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1974 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1975 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1976 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1977 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heater Core: Locations Fig.14 Heater Core The heater core is located in the heater-A/C unit housing, under the instrument panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1981 Heater Core: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DO NOT OPEN THE RADIATOR DRAIN-COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1982 Heater Core: Description and Operation Fig.51 Heater Core HEATER CORE The heater core is located in the heater-A/C unit housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. One end of the core is fitted with a molded plastic tank that includes the integral heater core hose nipples. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Cooling System for more information on the engine cooling system, the engine coolant and the heater hoses. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1983 Heater Core: Service and Repair HEATER CORE WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: DO NOT OPEN THE RADIATOR DRAIN-COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. REMOVAL 1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to: "Engine, Cooling, and Exhaust : Cooling System : Service and Repair" See: Service and Repair 3. Evacuate the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Heating and Air Conditioning/Service and Repair 4. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 5. Remove the refrigerant lines from the evaporator connections. 6. Remove the heater core coolant supply hoses from the heater core. INSTALLATION Refer to HVAC Housing Assembly for heater core installation procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service Precautions Heater Hose: Service Precautions 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. - When installing hoses to heater core inlet or outlet nipples DO NOT exert excessive pressure. The heater core may become damaged and leak engine coolant. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement - LHD HEATER INLET HOSE - LHD 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. Fig.54 Heater Hose Assembly - LHD 2.0L (Typical 2.4L) 2. Using spring tension clamp pliers (or equivalent), to remove clamps at end of heater hose to be removed. 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Heater Inlet Hose Replacement - RHD HEATER INLET HOSE - RHD 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1989 1. Drain engine cooling system. Fig.46 Heater Hose Assembly - RHD 2.0L 2. Using spring tension clamp pliers (or equivalent), to remove clamps at end of heater hose to be removed 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1990 Heater Hose: Service and Repair Heater Return Hose Replacement Heater Return Hose Replacement - LHD HEATER RETURN HOSE - LHD CAUTION: When removing hoses from the heater core inlet nipples DO NOT exert excessive 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. Fig.54 Heater Hose Assembly - LHD 2.0L (Typical 2.4L) 2. Using spring tension clamp pliers (or equivalent), to remove the clamps at the end of the heater hoses to be removed. 3. Carefully rotate the hose back and forth while pulling away from the connector nipple. INSTALLATION CAUTION: When installing hoses to heater core inlet or outlet nipples DO NOT exert excessive pressure. The heater core may become damaged and leak engine coolant. 1. Carefully rotate the hose back and forth while pushing the hose onto the connector nipple. 2. Using spring tension pliers, install the clamps at the end of the heater hose being installed. 3. Refill the cooling system. Heater Return Hose Replacement - RHD HEATER RETURN HOSE - RHD CAUTION: When removing hoses from the heater core inlet nipples DO NOT exert excessive pressure. The heater core may become damaged and Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1991 leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. Fig.46 Heater Hose Assembly - RHD 2.0L 2. Using spring tension clamp pliers (or equivalent), to remove the clamps at the end of the heater hoses to be removed. 3. Carefully rotate the hose back and forth while pulling away from the connector nipple. INSTALLATION 1. Carefully rotate the hose back and forth while pushing the hose onto the connector nipple. 2. Using spring tension pliers, install the clamps at the end of the heater hose being installed. 3. Refill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL 1. Drain the cooling system. 2. Turn the draincock 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 in. lbs.). 3. Fill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation COOLING SYSTEM PRESSURE CAP DESCRIPTION The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97 - 124 kPa (14 - 18 psi). There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant reserve/recovery system container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached. OPERATION The pressure cap allows the cooling system to operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point; this allows increased radiator cooling capacity. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve container. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 INSPECTION Hold the cap in your hand, top side up. The vent valve at the bottom of the cap should open. If the rubber gasket has swollen, preventing the valve from opening, replace the cap. Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve and the rubber gasket, replace the cap. Do not use a replacement cap that has a spring to hold the vent shut. A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2001 Radiator Cap: Component Tests and General Diagnostics Cooling System Pressure Relief Testing COOLING SYSTEM PRESSURE RELIEF TESTING WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, THE 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. The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at the filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow 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. 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 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. Radiator Cap Testing COOLING SYSTEM PRESSURE CAP TESTING Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2002 Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700. Working the plunger, bring 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 pressure cap. CAUTION: The Cooling System Tester Tool 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 tool upside down and recheck pressure cap to confirm that cap is bad. If the pressure cap tests properly while positioned on Cooling System 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 2003 Radiator Cap: Service and Repair CLEANING Use only a mild soap to clean the pressure cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2008 Radiator Fan Relays Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2009 Radiator Fan High Relay (1.6L/2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2010 Radiator Cooling Fan Motor Relay: Testing and Inspection Test 1 - 4 Test 5 SYMPTOM CHECKING RADIATOR FAN RELAY OUTPUT POSSIBLE CAUSES - Radiator fan relay operation - Ground circuit open - Radiator fan motor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2011 - Fused B+ circuit - Radiator fan relay output circuit - Radiator fan relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Application and ID Coolant Temperature Sensor / Switch HVAC: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Climate Controls .................................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2020 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2021 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2022 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2023 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Opening Temperature ......................................................................................................................... ..................................................................... 195 °F Full Opening Temperature ................................. ..................................................................................................................................................... 216 °F Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2027 Thermostat: Description and Operation DESCRIPTION The engine thermostat is located on the left front side (radiator side) of the cylinder head 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. A relief in the thermostat housing/outlet connector is provided for the O-ring. OPERATION The engine thermostat is a wax pellet driven, reverse poppet choke type. It is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 to 93° C (192 to 199° F). Also, the thermostat will automatically reach wide open, to accommodate unrestricted 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. A thermostats 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2028 Thermostat: Testing and Inspection ENGINE THERMOSTAT TESTING 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, a Diagnostic Trouble Code (DTC) will be set. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2029 Thermostat: Service and Repair REMOVAL 1. Drain cooling system to the thermostat level or below. 2. Remove coolant recovery/reserve system hose and radiator upper hose. 3. Remove thermostat/engine outlet connector bolts. 4. Remove thermostat and O-ring assembly INSTALLATION 1. Clean all sealing surfaces. 2. Place the new thermostat assembly into the thermostat housing/outlet connector. Align vent with notch in cylinder head. 3. Install thermostat housing/outlet connector onto cylinder head and tighten bolts to 12.5 Nm (110 in. lbs.). 4. Install the radiator upper hose. 5. Connect the coolant recovery/reserve system hose. 6. Fill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing/Water Outlet Connector-Screws 105 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Inlet Tube to Engine Block-Bolt 105 in.lb Water Pump to Engine Block-Bolts 105 in.lb Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2036 Water Pump: Description and Operation DESCRIPTION The water pump has a diecast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the cylinder block and is driven by the timing belt. Cylinder block to water pump sealing is provided by a rubber O-ring. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. OPERATION The water pump is the heart of the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, and radiator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2037 Water Pump: Testing and Inspection WATER PUMP DIAGNOSIS A quick flow test to determine water pump operation is check for proper heater operation. A defective pump will not circulate heated coolant through the heater hoses. An additional flow test can by performed by the following the procedures below: WARNING: DO NOT remove radiator cap if the cooling system is hot or under pressure. 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2038 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts. 3. Drain the cooling system. 4. Remove power steering pump attaching bolts and set pump and assembly aside. Power steering lines do not need to be disconnected. 5. Remove upper and lower torque isolator struts. 6. Support the engine from bottom and remove right engine mount attaching bolt. 7. Remove right engine mount bracket. 8. Remove the timing belt. 9. Remove the timing belt tensioner. 10. Remove camshaft sprocket and rear timing belt cover. 11. Remove water pump attaching screws to engine and remove pump. INSPECTION Replace water pump body assembly if it has any of these defects: 1. Cracks or damage on the body 2. Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body 3. Loose or rough turning bearing. 4. Impeller rubs either the pump body or the engine block. 5. Impeller loose or damaged. 6. Sprocket or sprocket flange loose or damaged. INSTALLATION 1. Apply Mopar Dielectric Grease to O-ring before installation. 2. Install new O-ring gasket in water pump body O-ring groove. CAUTION: Ensure O-ring gasket is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring, resulting in a coolant leak. 3. Assemble pump body to block and tighten screws to 12 Nm (105 in. lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2039 4. Rotate pump by hand to check for freedom of movement. 5. Install timing belt rear cover and camshaft sprocket. 6. Install timing belt tensioner. 7. Install the timing belt. 8. Install the engine right mount bracket. 9. Install the upper and lower torque isolator struts. 10. Fill the cooling system. 11. Install the accessory drive belts. 12. Perform camshaft and crankshaft timing relearn procedure as follows: ^ Connect the DRB 1116 scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel near the steering column. ^ Turn the ignition switch on. ^ Access "Engine" diagnostics. ^ Select "Miscellaneous" option. ^ Select "ReLearn Cam Crank" option and follow directions on DRB III screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Catalytic converter to exhaust manifold flange-fasteners 250 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2044 Catalytic Converter: Description and Operation DESCRIPTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2045 An under-floor catalytic converter is used on all three converter packages; EURO, Low Emission Vehicle (LEV), and the High Output engine. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. An exhaust flex-joint coupling secures the catalytic converter to the exhaust manifold by using four fasteners and a gasket for sealing. The flex-joint is serviced with the catalytic converter. CAUTION: When servicing the catalytic converter, care must be exercised not to dent or bend the flexjoint. Should this occur, the flex-joint will eventually fail and require the catalytic converter to be replaced. Do not allow the exhaust system to hang unsupported. If the isolators are removed and the catalytic converter is still attached to the exhaust manifold, failure to the flex joint will result. OPERATION The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases. Specifically, HC and CO emissions are converted into water (H20) and Carbon Dioxide (C02). Oxides of Nitrogen (NOx) are converted into elemental Nitrogen (N) and water. The three-way catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1. The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a high oxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to convert the gases. This is known as catalyst "punch through." Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of catalyst performance. Refer to the appropriate Diagnostic Information for diagnosis of a catalyst related Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2046 Diagnostic Trouble Code (DTC). The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders, if exhaust system is equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. This deterioration of the catalyst core can result in excessively high emission levels, noise complaints, and exhaust restrictions. Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system/floor pan temperatures because of no air movement under the vehicle. The flex joint allows flexing as the engine moves, preventing breakage that could occur from the back-and-forth motion of a transverse mounted engine. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements) and between model years. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2047 Catalytic Converter: Service and Repair REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. 1. Remove muffler and exhaust pipe. 2. Disconnect the downstream oxygen sensor electrical connector. 3. Remove the exhaust manifold support bracket (LEV only). 4. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle. 5. Remove and discard the flange gasket. NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used. INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. Check catalytic converter for a flow restriction. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2048 NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the Appropriate Diagnostic Information for test procedures. INSTALLATION NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked. 1. Assemble catalytic converter to exhaust manifold connection. Use a new flange gasket. 2. Install exhaust manifold support bracket (LEV only). Tighten M10 bolt to 54 Nm (40 ft. lbs.), M12 bolt to 95 Nm (70 ft. lbs.), and nut to 28 Nm (250 in. lbs.). 3. Install bolt attaching manifold support bracket to the heat shield (NLEV only). Tighten bolt to 28 Nm (250 in. lbs.). 4. Assemble muffler and exhaust pipe to catalytic converter. Install muffler and pipe support isolators to the underbody 5. Tighten the catalytic converter to exhaust manifold fasteners to 28 Nm (250 in. lbs.). 6. Working from the front of the system; align each component to maintain position and proper clearance with under body components. Tighten all slip joint band clamps to 47 Nm (35 ft. lbs.). CAUTION: Exhaust band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced. 7. If removed, install downstream oxygen sensor. 8. Connect downstream oxygen sensor electrical connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold to Cylinder Head 200 in.lb Exhaust Manifold Support Bracket M8 Bolts 250 in.lb Fed and LEV M10 Bolts 40 ft.lb M12 Bolts 70 ft.lb Exhaust Manifold Support Bracket 40 ft.lb ULEV Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2052 Exhaust Manifold: Description and Operation EXHAUST MANIFOLD - HIGH OUTPUT DESCRIPTION The exhaust manifold is a welded construction using lightweight tubular steel with stamped plate steel mounting flanges. The manifold attaches to the cylinder head. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2053 Exhaust Manifold: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Remove bolt attaching the wire harness heat shield to the exhaust manifold support bracket. 4. Remove exhaust manifold support bracket. 5. Remove fasteners attaching exhaust system flex joint to exhaust manifold flange. Move exhaust system rearward to clear flange studs. 6. Lower vehicle. 7. Disconnect make-up air hose from rear of cylinder head cover. 8. Disconnect oxygen sensor connector and harness clip. 9. Remove heat shield attaching bolts. 10. Remove upper heat shield for access to manifold bolts. 11. Remove exhaust manifold bolts. 12. Remove exhaust manifold from top of vehicle, between the cylinder head and cowl. INSTALLATION 1. Position exhaust manifold and gasket in place. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2054 2. Install exhaust manifold bolts and tighten in sequence shown to 23 Nm (200 in. lbs.). 3. Position lower and upper heat shield on exhaust manifold. Install heat shield bolts and tighten to 11 Nm (95 in. lbs.). 4. Connect oxygen sensor electrical connector and harness clip. 5. Connect make-up air hose on cylinder head cover port. 6. Raise vehicle. 7. Install new flex joint to manifold flange gasket. 8. Attach exhaust system to manifold flange and tighten fasteners to 28 Nm (250 in. lbs.). 9. Install exhaust manifold support bracket and tighten fasteners. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2055 10. Install bolt attaching wire harness heat shield to support bracket. 11. Lower vehicle. 12. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair INTERMEDIATE PIPE REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME. 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. Remove the muffler. 3. Loosen band clamp at the catalytic converter to intermediate pipe joint 4. Remove intermediate pipe support isolator. Separate at slip joint and remove intermediate pipe. 5. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). INSTALLATION When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2059 1. Assemble intermediate pipe to catalytic converter and the isolator support to the underbody. 2. Install the muffler to intermediate pipe and the isolator supports to the underbody 3. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 4. Tighten all band clamps to 47 Nm (35 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced.* NOTE: ^ *To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. ^ Maintain proper clamp orientation when replacing with new clamp. 5. Connect the exhaust system ground strap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation DESCRIPTION The heat shields,, and are needed to protect both the vehicle 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 2063 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 2064 Heat Shield: Service and Repair REMOVAL 1. Raise vehicle on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 2065 2. Remove fasteners attaching heat shield to under body, or engine component. 3. Remove heat shield(s). INSTALLATION 1. Position heat shield to underbody, or engine component. 2. Install and tighten heat shield fasteners,,, or 3. Inspect heat shield to exhaust system clearances and adjust as necessary. 4. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME. 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. Remove exhaust system ground strap. 3. Loosen band clamp and remove support isolators at muffler. Remove muffler from exhaust pipe. 4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). INSTALLATION When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. 1. Install the muffler to intermediate pipe and the isolator supports to the underbody. 2. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2069 3. Tighten all band clamps to 47 Nm (35 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced.* NOTE: ^ *To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. ^ Maintain proper clamp orientation when replacing with new clamp. 4. Connect the exhaust system ground strap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Body Control Module: Electrical Diagrams Airbag System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 Audio System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 CD Changer Compass/Temperature Mirror Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 Exterior Lighting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 Instrument Cluster Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 Interior Lighting Power Door Locks/RKE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Vehicle Communication Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2111 Body Control Module: Vehicle Damage Warnings Electrical Testing 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description Identification Of System The vehicle systems that are part of the "body" system are: - Airbag System - Audio - Compass/Temperature Mirror - Instrument Cluster - Interior Lighting - Power Door Locks/Remote Keyless Entry - Vehicle Communications - Vehicle Theft Security System System Description The body system on the 2003 PL consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Vehicle Communication See: Functional Operation/Vehicle Communication of this general information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2114 Body Control Module: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. DRIVER AIRBAG (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation, The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2115 PASSENGER AIRBAG (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). WARNING: REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) They are located on the left and right B-post. The SIACM perform self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ACM once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned on. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. SEAT AIRBAGS The Left and Right seat airbag modules are located in the outboard end of the front seat backs. The airbag module contains a bag, an inflator (a small canister of highly compressed argon gas) and a mounting bracket. The seat airbag module cannot be repaired and must be replaced if deployed or in any way damaged. When supplied with the proper electrical signal the inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. NOTE: It will be necessary to remove the seat back trim to gain access to the seat airbag module connector when diagnosing the seat airbag system. WARNING: THE SEAT AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SPECIAL TOOLS Some airbag diagnostic tests use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2116 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: * Erase the stored codes * Place the ignition in the Run position * Wiggle the wire harness and connectors * Rotate the steering wheel from stop to stop * Recheck for active codes periodically as you work through the system. Audio System AUDIO SYSTEM The audio system on the 2003 PL consists of a radio that communicates over the PCI bus. The speakers are located in the instrument panel, the front doors and the rear "D" pillars. The instrument panel speakers are a tweeter type speaker for high frequency. The front door speakers are a woofer/midrange type speaker. The rear "D" pillar speakers are a full range type speaker. If one of the speaker circuits experiences a short, the other speakers on that output channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which the DRB III(R) can display. The in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect , such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in the chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2117 disc in that chamber. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Compass/Temperature Mirror COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2118 Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2119 magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2120 If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Exterior Lighting EXTERIOR LIGHTING The Headlamps are controlled by the Instrument Cluster. The Instrument Cluster is also referred to as a "Smart Cluster". It receives and sends messages to other modules through the PCI BUS circuit. The Headlamps are wired through the cluster and then go to the Fuse Block to the lamps. Each Headlamp has an independent fuse located in the Fuse Block. For vehicles equipped with Daytime Running Lamps, the DRL Module is integrated with the Instrument Cluster. Interior Lighting INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. Some of the features that it controls are the courtesy lamps, chime, and all instrument illumination. It receives and sends messages to other modules via the PCI bus circuit. The front turn signals are wired through the cluster and then go to the front lamps. For vehicles equipped with Daytime Running Lamps, the DRL module is built into the cluster. Power Door Locks/Remote Keyless Entry REMOTE KEYLESS ENTRY MODULE The Remote Keyless Entry module controls the Power Door Locks and the Vehicle Theft Security System (VTSS). It also wakes up the Instrument Cluster to turn on the illuminated entry when it senses a signal from the RKE transmitter. The module communicates with other modules via the PCI bus circuit. The RKE module monitors the Occupant Restraint Controller messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message along with the verification that the ignition is on and the vehicle speed is zero, it will provide the "enhanced accident response feature". This feature will cause the module to unlock-all doors immediately and the instrument cluster to turn the courtesy lamps on when the vehicle reaches 0 mph. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message, and receive body style information. Two transmitters are supplied with the vehicle but a total of 4 can be programmed to the module. The horn chirp on vehicle lock command is customer programmable. To limit the amount of battery drain during storage, the IOD fuse may be removed. VEHICLE THEFT SECURITY SYSTEM When the VTSS is armed, it will monitor the ignition switch status, ajar switches for the vehicle doors and decklid. Also monitored is a decklid security switch (knockout) for the cylinder lock. If the alarm is tripped, it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2121 Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, by using the driver door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of an open decklid security switch sense circuit. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with the driver door cylinder lock. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. VEHICLE THEFT SECURITY SYSTEM (Export Only) When the VTSS is armed, it Will monitor the interior of the vehicle for movement via an intrusion sensor (if equipped), the ignition switch status, ajar switches for the vehicle doors, decklid and hood. Vehicles without an intrusion sensor will have a decklid security switch (knockout) which will also be monitored. If the alarm is tripped, it will sound the vehicles horn or a battery backed siren for vehicles equipped with the intrusion sensor, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, or by using either door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of the hood ajar circuit being shorted (hood opened) or the decklid security switch circuit being open (if equipped). Defeating the intrusion sensor feature for vehicles so equipped can be done by three additional lock request to the RKE module within 5 seconds. Disarming is done by either a RKE unlock or turning the ignition on with a valid Sentry key. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. Vehicle Communication VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2003 PL: - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio (If equipped) - CD Changer (If equipped) - Compass/Temperature Mirror (If equipped) - Remote Keyless Entry Module (If equipped) - Sentry Key Immobilizer Module (If equipped) - Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2122 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III(R) lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the diagram for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at the module, or an open battery or ground circuit to the affected Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - No response received from any module on the PCI bus (except PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2123 Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III(R) may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Airbag Indicator On Without ACM Trouble Codes Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACM TROUBLE CODES POSSIBLE CAUSES - Airbag indicator on without ACM trouble codes - Instrument cluster problems No Response From Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2126 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2127 Test 3 - 4 SYMPTOM NO RESPONSE FROM ACM POSSIBLE CAUSES - Checking for voltage at ACM - Ground circuit open - PCI bus circuit open - Airbag control module AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2128 POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2129 CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2130 Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure No Response From Radio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2131 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2132 Test 4 - 6 SYMPTOM NO RESPONSE FROM RADIO POSSIBLE CAUSES - No response from radio - Open fused ignition switch output circuit - Open fused B+ circuit - Radio ground circuit open - Open PCI bus circuit - Radio Pause/Play Switch Inoperative Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2133 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2134 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2135 - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Compass/Temperature Mirror Does Calibrate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2136 Test 1 Test 2 SYMPTOM COMPASS/TEMPERATURE MIRROR DOES CALIBRATE POSSIBLE CAUSES - Calibration procedure - Compass/temperature mirror Compass/Temperature Mirror Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2137 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2138 Test 4 - 6 SYMPTOM COMPASS/TEMPERATURE MIRROR INOPERATIVE POSSIBLE CAUSES - No response - PCI bus - compass - Fused B(+) circuit short to ground - Fused B(+) circuit open - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Ground circuit open - Compass/temperature mirror High Beam Headlamps Will Not Turn Off Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2139 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Dimmer switch high beam output circuit short to voltage - Instrument cluster - Multifunction switch High Beam Headlamps Will Not Turn On Test 1 - 4 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2140 Test 5 - 7 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Open fused B+ - Dimmer switch low beam output circuit short to ground - Dimmer switch high beam output circuit short to ground - Open fuse - Dimmer switch low beam output circuit open - Instrument cluster - Multifunction switch Low Beam Headlamps Will Not Turn Off Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2141 Test 1 - 3 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Multifunction switch - Dimmer switch low beam output circuit short to voltage - Fuse block - Instrument cluster Low Beam Headlamps Will Not Turn On Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2142 Test 1 - 4 Test 5 - 6 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Multifunction switch - Fuse block - Dimmer switch low beam output circuit open - Instrument cluster - Open fused B+ to fuse block - Fused B+ circuit short to ground - B+ circuit breaker 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2143 All Gauges Inoperative Test 1 - 4 Test 5 - 6 SYMPTOM ALL GAUGES INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2144 POSSIBLE CAUSES - No response - PCI bus - No response - PCI bus - powertrain control module - No response - PCI bus - instrument cluster - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Instrument cluster ground circuit open - Instrument cluster Any or All Gauge Pointer(s) On Wrong Side of Stop Test 1 SYMPTOM ANY OR ALL GAUGE POINTER(S) ON WRONG SIDE OF STOP POSSIBLE CAUSES - Instrument cluster Any PCI Bus Indicator Inoperative Test 1 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2145 POSSIBLE CAUSES - LED defective - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2146 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake warning indicator circuit short to ground - Red brake warning indicator driver circuit short to ground - Park brake switch - Brake fluid level switch - Instrument cluster - Powertrain control module Brake Warning Indicator Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2147 Test 4 - 7 Test 8 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2148 POSSIBLE CAUSES - Brake warning indicator circuit open - Indicator led - Brake fluid level switch - Park brake switch - Red brake warning indicator driver circuit open - Brake fluid level switch ground circuit open - Instrument cluster - Powertrain control module Front Fog Lamp Indicator Inoperative Test 1 - 2 SYMPTOM FRONT FOG LAMP INDICATOR INOPERATIVE POSSIBLE CAUSES - Front fog lamp indicator circuit open - Indicator led - Instrument cluster Fuel Gauge Inaccurate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2149 Test 1 - 2 Test 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Fuel level sensor - Intermittent condition - Instrument cluster High Beam Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2150 Test 1 - 2 SYMPTOM HIGH BEAM INDICATOR INOPERATIVE POSSIBLE CAUSES - High beam indicator circuit open - High beam indicator bulb - Instrument cluster Instrument Cluster Dimming Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2151 Test 1 - 3 SYMPTOM INSTRUMENT CLUSTER DIMMING INOPERATIVE POSSIBLE CAUSES - DTC present - Headlamp switch output circuit open - Illumination bulb - Instrument cluster Low Oil Pressure Indicator Always on Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2152 Test 1 - 3 SYMPTOM LOW OIL PRESSURE INDICATOR ALWAYS ON POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit short to ground - Powertrain control module - Instrument cluster Low Oil Pressure Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2153 Test 1 - 3 Test 4 SYMPTOM LOW OIL PRESSURE INDICATOR INOPERATIVE POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit open - Indicator led - Powertrain control module - Instrument cluster One Gauge Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2154 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE POSSIBLE CAUSES - Powertrain control module DTCs - Instrument cluster PRND or Autostick Indicator Display Inaccurate or Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2155 Test 1 - 2 SYMPTOM PRND OR AUTOSTICK INDICATOR DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - DTC present - Intermittent condition - Instrument cluster Rear Fog Lamp Indicator Inoperative - BUX Only Test 1 - 2 SYMPTOM REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY POSSIBLE CAUSES - Rear fog lamp indicator circuit open - Indicator led - Instrument cluster Seat Belt Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2156 Test 1 - 4 Test 5 SYMPTOM SEATBELT INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator led - Seat belt indicator circuit open - Seat belt switch ground open - Seat belt switch - Instrument cluster Temperature Display Inoperative or Wrong (2.0L Only) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2157 Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INOPERATIVE OR WRONG (2.0L ONLY) POSSIBLE CAUSES - DTC present in PCM - Ambient temperat1jre sensor - Compass/temperature mirror VF Display Inoperative Test 1 SYMPTOM VF DISPLAY INOPERATIVE POSSIBLE CAUSES - Instrument cluster Courtesy Lamps Inoperative - All Lamps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2158 Test 1 - 3 SYMPTOM COURTESY LAMPS INOPERATIVE - ALL LAMPS POSSIBLE CAUSES - Fused B+ circuit open - Instrument cluster - courtesy lamp open - Courtesy lamp driver circuit open - Intermittent condition Courtesy Lamps On At All Times Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2159 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2160 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2161 Test 8 - 10 SYMPTOM COURTESY LAMPS ON AT ALL TIMES POSSIBLE CAUSES - Drivers door ajar switch - Drivers door ajar switch sense wire short to ground - Remote keyless entry module - if equipped - Instrument cluster - Instrument cluster - Panel lamps dimmer signal wire short to ground - Multifunction switch - Open door ajar switch - Remote keyless entry module - if equipped - Passenger door ajar/RKE sense wire short to ground - Instrument cluster - Courtesy lamp driver circuit short to ground - Instrument cluster Illuminated Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2162 Test 1 - 2 SYMPTOM ILLUMINATED ENTRY INOPERATIVE POSSIBLE CAUSES - Courtesy lamps operational - Intermittent condition - Illuminated entry not enabled All Door Locks Inoperative Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2163 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2164 Test 8 - 13 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2165 Test 14 - 16 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Decklid release relay output wire short to ground - Fused B(+) circuit open - Fused B(+) wire short to ground - Ground circuit open - Door lock relay output circuit open - Driver door unlock relay output short to door lock relay output - Driver door unlock relay output wire short to ground - Door lock relay output wire short to ground - Door unlock relay output short to door lock relay output - Decklid release solenoid-shorted - Door unlock relay output wire short to ground - Defective fuse #14 - RKE module - B(+) short to ground - RKE module - relays open - RKE module - shorted All Doors Except Driver Fail to Lock and Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2166 Test 1 - 4 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO LOCK AND UNLOCK POSSIBLE CAUSES - RKE module - open door unlock relay output - Door unlock relay output wire open - Door lock relay output wire open - Open motors All Doors Except Driver Fail to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2167 Test 1 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO UNLOCK POSSIBLE CAUSES - Door unlock relay output circuit short to ground - Remote keyless entry module unlock relay Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTOMATIC DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Auto door locks not enabled - Door ajar status - PCM DTC's present - RKE module defective - auto locks inoperable Decklid Solenoid Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2168 Test 1 - 4 SYMPTOM DECKLID SOLENOID INOPERATIVE POSSIBLE CAUSES - Solenoid ground open - Decklid release solenoid open - Decklid release relay output wire open - RKE module - decklid relay open Doors Lockable With Key In Ignition and Driver Door Open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2169 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2170 Test 4 - 10 SYMPTOM DOORS LOCKABLE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Driver door ajar switch - open - Open driver door ajar switch sense to RKE module - Ignition switch open - Key-in ignition switch sense wire open - Open driver door ajar switch sense to cluster - Instrument cluster - key-in ignition open - Instrument cluster defective-driver door ajar open - RKE module defective-open driver door ajar Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2171 Driver Door Fails to Lock and Unlock Test 1 - 3 Test 4 SYMPTOM DRIVER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - RKE module - open driver unlock circuit - Driver door lock motor - open - Driver door lock relay output wire open - Driver door unlock relay output wire open Driver Door Fails to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2172 Test 1 SYMPTOM DRIVER DOOR FAILS TO UNLOCK POSSIBLE CAUSES - Driver door unlock relay output wire short to ground - RKE module defective - driver unlock open One Passenger Door Fails to Lock and Unlock Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2173 Test 4 - 6 SYMPTOM ONE PASSENGER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - Door lock motor open - Door unlock relay output wire open - Door lock relay output wire open - Door unlock relay output wire short to ground - Door unlock relay output short to door lock relay output - Door lock relay output wire short to ground Remote Keyless Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2174 Test 1 - 3 Test 4 - 5 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - Test RKE transmitter Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2175 - RKE transmitter - inoperative - RKE module - RKE module - receiver inoperable Alarm Trips On Its Own Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition All Doors Fail to Lock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2176 Test 1 - 4 Test 5 SYMPTOM ALL DOORS FAIL TO LOCK POSSIBLE CAUSES - Door lock relay output circuit short to ground - Decklid release relay output short to door lock relay output - Decklid release relay output short to driver door unlock relay output - Decklid release relay output short to door unlock relay output - Remote keyless entry module - unlock ground open All Locks Inoperative From A Door Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2177 Test 1 - 3 Test 4 - 6 SYMPTOM ALL LOCKS INOPERATIVE FROM A DOOR LOCK SWITCH POSSIBLE CAUSES - DTC present Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2178 - Door switch ground wire open - Door switch MUX wire short to voltage - Door switch MUX wire open - Door lock switch open - Remote keyless entry module - high voltage - Remote keyless entry module - low voltage Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH DURING ALARM POSSIBLE CAUSES - Dimmer switch low beam output circuit open - Remote keyless entry module Horn Fails to Sound When Alarm Is Tripped Test 1 SYMPTOM HORN FAILS TO SOUND DURING ALARM POSSIBLE CAUSES - Horn relay control circuit open - Remote keyless entry module Intrusion Sensor Cannot Be Disabled Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2179 Test 1 SYMPTOM INTRUSION SENSOR CANNOT BE DISABLED (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Intrusion Sensor Fails to Trip VTSS Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2180 Test 4 - 6 SYMPTOM INTRUSION SENSOR FAILS TO TRIP VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Open fused B(+) circuit - Open ground circuit - Intrusion sensor signal circuit open - Intrusion sensor signal circuit shorted to ground - Intrusion sensor - Remote keyless entry module Intrusion Sensor Repeatedly Triggers VTSS Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2181 SYMPTOM INTRUSION SENSOR REPEATEDLY TRIGGERS VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Open Driver Door Fails to Trip Alarm Test 1 - 3 SYMPTOM OPEN DRIVER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Remote keyless entry module Open Passenger Door Fails to Trip Alarm Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2182 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2183 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2184 Test 7 - 8 SYMPTOM OPEN PASSENGER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Left rear door ajar switch ground circuit open - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Right rear door ajar switch ground circuit open - Passenger door ajar/RKE sense circuit open - Left rear door ajar switch - Passenger door ajar/RKE sense circuit open - Right rear door ajar switch - Passenger door ajar/RKE circuit open - Passenger door ajar/RKE sense circuit open - Remote keyless entry module - RKE module - passenger door ajar sense Park Lamps Fail to Flash During Alarm Test 1 SYMPTOM PARK LAMPS FAIL TO FLASH DURING ALARM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2185 POSSIBLE CAUSES - Park lamp switch output circuit open - Remote keyless entry module VTSS Fails to Arm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Fails to Arm From Passenger Door Cylinder Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2186 Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM PASSENGER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Passenger door switch MUX circuit open - Passenger cylinder lock switch faulty VTSS Fails to Arm/Disarm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM/DISARM FROM DRIVER DOOR CYLINDER LOCK SWITCH Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2187 TEST NOTE This symptom is diagnosed using the test VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY). POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Indicator Fails to Flash Test 1 - 3 SYMPTOM VTSS INDICATOR FAILS TO FLASH POSSIBLE CAUSES - Remote keyless entry module - Instrument cluster - VTSS indicator driver circuit open - VTSS led open VTSS Indicator Stays On Steady During Arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2188 Test 1 - 5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2189 Test 6 - 8 SYMPTOM VTSS INDICATOR STAYS ON STEADY DURING ARMING POSSIBLE CAUSES - Decklid security switch sense circuit open (if equipped) - Decklid security switch ground circuit open (if equipped) - Decklid security switch (if equipped) - Hood ajar switch sense circuit shorted to ground (if equipped) - Hood ajar switch (if equipped) - RKE module - VTSS indicator - RKE module - hood ajar (if equipped) - RKE module - decklid security (if equipped) VTSS Siren Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2190 Test 4 - 6 SYMPTOM VTSS SIREN INOPERATIVE (EXPORT ONLY) POSSIBLE CAUSES - Siren functional test - Open fused B(+) circuit - Open ground circuit - Faulty siren - Siren control circuit open - Siren control circuit shorted to ground - Remote keyless entry module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2191 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Road Testing ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. during the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2192 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: Erase the stored codes - Place the ignition in the Run position - Wiggle the wire harness and connectors - Rotate the steering wheel from stop to stop - Recheck for active codes periodically as you work through the system. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2193 The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Glossary of Terms ABS Antilock Brake System ACM Airbag Control Module AECM Airbag Electronic Control Module (ACM) ASDM Airbag System Diagnostic Module (ACM) BUX Built-Up Export CAB Controller Antilock Brake CTM Compass/Temperature Mirror DAB Driver Airbag DLC Data Link Connector DTC Diagnostic Trouble Code EMIC Electro/Mechanical Instrument Cluster LSIACM Left SIACM NGC Next Generation Controller PAB Passenger Airbag PCI Programmable Communication Interface (Vehicle Communication Bus) PCM Powertrain Control Module PDC Power Distribution Center PWM Pulse Width Modulated RKE Remote Keyless Entry RSIACM Right SIACM SAB Side Airbag SIACM Side Impact Airbag Control Module SKIM Sentry Key Immobilizer Module SKIS Sentry Key Immobilizer System SQUIB Also Called Initiator (Located In Rear Of Airbag Module) TCM Transmission Control Module VFD Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2194 Body Control Module: Scan Tool Testing and Procedures DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2195 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. DRB III Safety Information DRB III (R) SAFETY INFORMATION WARNING: EXCEEDING THE LIMITS OF THE DRB III (R) MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLE FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS. Follow the vehicle manufacture's service specifications at all times. Do not use the DRB Ill(R) if it has been damaged. Do not use the test leads if the insulation is damaged or if metal is exposed. To avoid electrical shock, do not touch the test leads, tips, or other circuit being tested. Choose the proper range and function for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Do not exceed the limits shown in the table. Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. The circuit being tested must be protected by a 10A fuse or circuit breaker. Use the low current shunt to measure circuits up to 10A. Use the higher current clamp to measure circuits exceeding 10A. When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. When measuring current, connect the meter in series with the load. Disconnect the live test lead before disconnecting the common test lead. When using the meter function, keep the DRB III (R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2196 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read out box) Jumper Wires Ohmmeter Voltmeter Test Light 8310 Airbag Load Tool 8443 SRS Airbag System Load Tool Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2205 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2206 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2207 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2208 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2209 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2210 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2211 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2212 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2218 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2219 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2220 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2225 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2226 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2227 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2228 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2229 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2230 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2231 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2232 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2238 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2239 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2240 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 2241 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws 4 Nm 35 In. Lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 2244 Powertrain Control Module: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 2245 Fig. 12 Engine (Right Front) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 2246 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 2247 Fig. 43 Engine (Right Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views Powertrain Control Module: Connector Views Powertrain Control Module C1 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 2250 Powertrain Control Module C2 (2.0L NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 2251 Powertrain Control Module C3 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 2252 Powertrain Control Module C4 (EATX NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read Powertrain Control Module: Description and Operation Important - Please Read IMPORTANT (NGC) New for the 2003 PL is a combined Powertrain Control Module and Transmission Control Module in a single control module. This new module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 2255 Powertrain Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Fig.5 PCM 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, transmission, and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Ambient Air temperature Sensor - ASD Sense - Baro/Tip (Turbo) - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 2256 - Clutch Upstop Switch (1.6L) - Clutch Interlock - Crankshaft Position Sensor - Cruise Control Switch - Electronic Throttle Control (1.6L only) - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - J1850 - Knock Sensor (1.6, 2.0, 2.4L only) - Natural Vacuum Leak Detection (NVLD) - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Pedal Position Sensor (1.6L has 2 sensors) - Power Steering Pressure Switch - SCI Receive - Speed Control Switches - Throttle Position Sensor (1.6L has 2 TPS Sensors) - Transmission Control Relay (Switched B+) - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transmission Pressure Switches (L/R, 2/4, OD) - Transmission Range Sensor (TRS) - Transmission Oil Temperature Sensor (Integral to TRS) - Vehicle Speed Sensor (MTX-equipped models). NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp (Bus Message) - SCI Transmit - Proportional Purge Solenoid - EGR Solenoid - Electronic Throttle Control (1.6L only) - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor (2.0/2.4L) - Ignition Coils - J1850 - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Oxygen Sensors Heater Controls - Radiator Fan Relays - Speed Control Solenoids (2.0/2.4L) - Transmission Control Relay - Transmission Solenoids (LR/CC, 2/4, OD, and UD) - Transmission PRNDL Position (to Cluster) - Transmission Torque Reduction Request (Internal to PCM) - Transmission Temperature (Internal to PCM and a Bus Message) - Vehicle Speed (Manual Transmission) - 2 Electronic Throttle Control Outputs (1.6L) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 2257 The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. Air conditioning sense - Battery voltage - Battery temperature - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The Auto Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off from the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Powertrain Control Module Connectors The PCM is an engine and transmission controller module all in one, if the vehicle is equipped with an automatic transmission. The PCM uses four wiring harness connectors to receive and send engine and transmission data. To ease assembly, the mating wiring harness connector is color-coded. Each module connector cavity has its own unique color identification stripe located on the outside of each connector cavity. The PCM module utilizes four wiring harness connectors as described: - Connector Cavity A is for Power & Ground (Black) - Connector Cavity B is for Engine Side (Orange) - Connector Cavity C is for Headlamp & Dash (White) - Connector Cavity D is for Transmission (Green) If equipped. NOTE: Connector Cavities A, B, C, And D must be connected prior to battery connection and ignition key on to avoid setting erroneous controller fault codes. It is also recommended that cavity A connector is made prior to any other connectors. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) An important function of the PCM is to monitor Transmission Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 2258 Fig.6 Example Of CVI Calculation By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRBIII Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: TRANSMISSION SHIFT SCHEDULES The PCM is programmed to allow it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 2259 - Software calibration level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Electronic Throttle Control (1.6L) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Pedal Position Sensor (1.6L) - Throttle position sensor - Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 2260 Powertrain Control Module: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING PCM POWER AND GROUND CIRCUITS POSSIBLE CAUSES - (A14) PCM fused B+ circuit - (A41) PCM fused ignition switch output circuit - (Z12) PCM ground circuits Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2263 Powertrain Control Module: Service and Repair Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2264 Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2265 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL Fig.4 Battery Cable 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2266 Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2267 Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2268 Powertrain Control Module: Service and Repair PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2269 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2270 Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2271 Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2272 Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Removal and Installation REMOVAL Fig.4 Battery Cable Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2273 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2274 Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2275 When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Obtaining Diagnostic Trouble Codes BULB CHECK Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Programming the Powertrain Control Module > Page 2276 Key on: Bulb illuminated until vehicle starts, as long as all once per trip (readiness) monitors completed. If monitors have not been completed, then: Key on: bulb check for about 5 to 8 seconds, lamp then flashes if once per trip (readiness) monitors have not been completed until vehicle is started, then MIL is extinguished. OBTAINING DTC'S USING DRB SCAN TOOL 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 instrument panel; near the steering column. 2. Turn the ignition switch on and access the "Read Fault" screen. 3. Record all the DTC's and "freeze frame" information shown on the DRB scan tool. 4. To erase DTC's, use the "Erase Trouble Code" data screen on the DRB scan tool. Do not erase any DTC's until problems have been investigated and repairs have been performed. Pinion Factor Setting NOTE: This procedure must be performed if the PCM/TCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM/TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain/ Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRBIII scan tool. 1. Plug the DRBIII scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRBIII scan tool screen. Quick Learn Procedure The quick learn procedure requires the use of the DRBIII scan tool. This program allows the PCM/ TCM to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain/Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBIII indicates the procedure is complete - The calculated oil temperature must be above 60° and below 200° 1. Plug the DRBIII scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRBIII to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2280 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2285 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2286 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump 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 the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2290 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Variable Induction Control Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Variable Induction Control Relay > Component Information > Locations > Page 2294 Manifold Tuning Valve Relay (RT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2301 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2302 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2303 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2304 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2308 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2312 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2313 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2314 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2315 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 2320 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2321 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2322 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2323 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2324 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2325 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig.11 Fuel Pump Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 2329 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 2330 Fuel Level Sensor: Service and Repair Fig.4 Fuel Pump/Level Sensor Electrical Connector Fig.5 Wire Terminal Locking Wedge Fig.6 Removing Wires From Connector Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 2331 Fig.7 Level Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2336 Intake Air Temperature (IAT) Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2337 Fig. 8 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2338 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2339 Fig. 48 Left Side Engine - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2340 Inlet Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2341 Intake Air Temperature (IAT) Sensor: Description and Operation Fig.18 Inlet Air Temperature Sensor INLET AIR TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct. The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2342 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the inlet air temperature sensor 3. Remove the air cleaner lid. 4. Disconnect the inlet air tube from the throttle body. 5. Remove inlet air tube from air cleaner lid. INSTALLATION 1. Install inlet air tube to air cleaner lid and tighten clamp. 2. Install inlet air tube to throttle body and tighten clamp. 3. Install air cleaner lid to air cleaner box. 4. Connect the inlet air temperature sensor electrical connector. 5. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2346 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Fig. 15 Engine (Top) (2.0L) - LHD Fig. 48 Engine (Top) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2350 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2351 Manifold Absolute Pressure Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2352 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.23 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezo-resistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key ON is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key ON the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2353 The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2354 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL Fig.24 MAP Sensor The MAP sensor attaches to the intake manifold plenum. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION The MAP sensor attaches to the intake manifold plenum. 1. Insert sensor into intake manifold while making sure not to damage O-ring seal. 2. Tighten mounting screws to 4.5 Nm (40 in. lbs.) torque for plastic manifold. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2358 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2363 Oxygen Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2364 Fig. 13 Engine (Left Rear) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2365 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2366 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2367 Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2368 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2369 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - 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 1/1. - 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2370 Oxygen Sensor: Description and Operation Fig.30 Types Of O2 Sensors Fig.27 Upstream Heated Oxygen Sensor 1/1 O2 SENSOR The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2371 Fig.28 Downstream Heated Oxygen Sensor 1/2 Fig.29 Heated Oxygen Sensor Systems The downstream heated oxygen sensor threads into the system depending on emission package. Federal package the O2S is mounted after the catalytic convertor, LEV package the O2S is mounted mid catalytic convertor, ULEV package is mounted between the catalytic convertor. A single sensor ground is used for all O2 sensors (2 sensors on 4 cyl. vehicles and 4 sensors on 6 cyl. vehicles). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2372 monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM uses pulse width modulation to control the ground side of the heater to regulate the temperature on 4 cyl. upstream O2 heater only. All other 4 cyl. and 6 cyl. O2 heaters do not use pulse width modulation. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (1/2) O2 Sensor Oxygen Sensor: Service and Repair Downstream (1/2) O2 Sensor REMOVAL Fig.32 Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 1. Raise vehicle. 2. Disconnect electrical connector from harness. 3. Disconnect sensor electrical harness from clips along body. Fig.33 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 5. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect sensor electrical harness from clips along body Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (1/2) O2 Sensor > Page 2375 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (1/2) O2 Sensor > Page 2376 Oxygen Sensor: Service and Repair Upstream (1/1) O2 Sensor REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig.31 Upstream Heated Oxygen Sensor Removal/Installation 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 4. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Plug sensor connector. 3. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 2377 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Remover/Installer - C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 2382 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 2383 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 2384 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2385 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2390 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2391 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2392 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2393 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2394 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 2400 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 2401 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 2402 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 2403 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 2404 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 2405 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 2406 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Connector Views Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2417 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2418 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2419 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2420 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2421 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2426 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 2431 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2432 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2433 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2434 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2435 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2436 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair "For information regarding this component please refer to steering column service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2444 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE ............................................................................................................................... ......................................... 400 ± 34 kPa (58 ± 5 psi) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2449 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2450 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2451 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 AIR CLEANER ELEMENT REMOVAL 1. Remove 5 screws from air cleaner element box lid. 2. Remove lid from air cleaner box. 3. Pull air cleaner up and out of air cleaner box. INSTALLATION 1. Install air cleaner element on to throttle body and push towards the throttle body and past lip in air cleaner box bottom (Fig. 10). 2. Install lid and tighten screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2463 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2467 The electronic ignition coil pack attaches directly to the valve cover. The 2.0 Liter (122 cu. inch) in-line four cylinder engine is a single over head camshaft with hydraulic lifters and four valves per cylinder design (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE ................................................................................................................................................. ........................................................ RESISTANCE # 1, # 4 ................................................................................................................................................. ..................................................... 2970 - 8910 ohms # 2, # 3 ................................................................................................................................................. ..................................................... 2360 - 7070 ohms Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2475 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature silicone materials. All spark plug cable leads are properly identified with cylinder numbers. The inside of most the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2476 Ignition Cable: Service and Repair REMOVAL 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. Remove spark plug cable from coil first. 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. INSTALLATION 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. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair Spark Plug Tube: Service and Repair SPARK PLUG TUBE REMOVAL 1. Remove the cylinder head cover. 2. Using locking pliers, remove the tube from the cylinder head. Discard old tube. INSTALLATION 1. Clean area around spark plug with Mopar parts cleaner or equivalent. 2. Apply Mopar Stud and Bearing Mount or equivalent to a new tube approximately 1 mm (0.039 inch) from the end in a 3 mm (0.118 inch) wide area. 3. Install sealer end of tube into the cylinder head. Then carefully install the tube using a hardwood block and mallet until the tube is seated into the bottom of the bore. 4. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation Spark Plug Tube Seal - Valve Cover: Description and Operation DESCRIPTION The spark plug tube seals are located in the cylinder head cover. These seals are pressed into the cylinder head cover to seal the outside perimeter of the spark plug tubes. If these seals show signs of hardness and/or cracking, they should be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation > Page 2484 Spark Plug Tube Seal - Valve Cover: Service and Repair REMOVAL 1. Remove the cylinder head cover. 2. Using an appropriate tool, carefully remove spark plug tube seals. Care should be taken not to damage cylinder head cover sealing surfaces. INSTALLATION 1. Clean all sealing surfaces. NOTE: Position seal with the concave side facing the installation tool. 2. Install seals using Special Tool MB-998306. Only hand pressure on tool is needed to install new seals. 3. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25 percent Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2488 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST 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. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRB III. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2497 Intake Air Temperature (IAT) Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2498 Fig. 8 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2499 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 2500 Fig. 48 Left Side Engine - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2501 Inlet Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2502 Intake Air Temperature (IAT) Sensor: Description and Operation Fig.18 Inlet Air Temperature Sensor INLET AIR TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct. The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2503 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the inlet air temperature sensor 3. Remove the air cleaner lid. 4. Disconnect the inlet air tube from the throttle body. 5. Remove inlet air tube from air cleaner lid. INSTALLATION 1. Install inlet air tube to air cleaner lid and tighten clamp. 2. Install inlet air tube to throttle body and tighten clamp. 3. Install air cleaner lid to air cleaner box. 4. Connect the inlet air temperature sensor electrical connector. 5. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2508 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2509 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2510 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2511 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2524 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2525 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2526 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2527 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2535 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2536 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2537 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 Body Control Module: Electrical Diagrams Airbag System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 Audio System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 CD Changer Compass/Temperature Mirror Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 Exterior Lighting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 Instrument Cluster Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Interior Lighting Power Door Locks/RKE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 Vehicle Communication Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2550 Body Control Module: Vehicle Damage Warnings Electrical Testing 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description Identification Of System The vehicle systems that are part of the "body" system are: - Airbag System - Audio - Compass/Temperature Mirror - Instrument Cluster - Interior Lighting - Power Door Locks/Remote Keyless Entry - Vehicle Communications - Vehicle Theft Security System System Description The body system on the 2003 PL consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Vehicle Communication See: Functional Operation/Vehicle Communication of this general information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2553 Body Control Module: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. DRIVER AIRBAG (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation, The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2554 PASSENGER AIRBAG (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). WARNING: REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) They are located on the left and right B-post. The SIACM perform self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ACM once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned on. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. SEAT AIRBAGS The Left and Right seat airbag modules are located in the outboard end of the front seat backs. The airbag module contains a bag, an inflator (a small canister of highly compressed argon gas) and a mounting bracket. The seat airbag module cannot be repaired and must be replaced if deployed or in any way damaged. When supplied with the proper electrical signal the inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. NOTE: It will be necessary to remove the seat back trim to gain access to the seat airbag module connector when diagnosing the seat airbag system. WARNING: THE SEAT AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SPECIAL TOOLS Some airbag diagnostic tests use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2555 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: * Erase the stored codes * Place the ignition in the Run position * Wiggle the wire harness and connectors * Rotate the steering wheel from stop to stop * Recheck for active codes periodically as you work through the system. Audio System AUDIO SYSTEM The audio system on the 2003 PL consists of a radio that communicates over the PCI bus. The speakers are located in the instrument panel, the front doors and the rear "D" pillars. The instrument panel speakers are a tweeter type speaker for high frequency. The front door speakers are a woofer/midrange type speaker. The rear "D" pillar speakers are a full range type speaker. If one of the speaker circuits experiences a short, the other speakers on that output channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which the DRB III(R) can display. The in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect , such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in the chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2556 disc in that chamber. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Compass/Temperature Mirror COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2557 Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2558 magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2559 If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Exterior Lighting EXTERIOR LIGHTING The Headlamps are controlled by the Instrument Cluster. The Instrument Cluster is also referred to as a "Smart Cluster". It receives and sends messages to other modules through the PCI BUS circuit. The Headlamps are wired through the cluster and then go to the Fuse Block to the lamps. Each Headlamp has an independent fuse located in the Fuse Block. For vehicles equipped with Daytime Running Lamps, the DRL Module is integrated with the Instrument Cluster. Interior Lighting INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. Some of the features that it controls are the courtesy lamps, chime, and all instrument illumination. It receives and sends messages to other modules via the PCI bus circuit. The front turn signals are wired through the cluster and then go to the front lamps. For vehicles equipped with Daytime Running Lamps, the DRL module is built into the cluster. Power Door Locks/Remote Keyless Entry REMOTE KEYLESS ENTRY MODULE The Remote Keyless Entry module controls the Power Door Locks and the Vehicle Theft Security System (VTSS). It also wakes up the Instrument Cluster to turn on the illuminated entry when it senses a signal from the RKE transmitter. The module communicates with other modules via the PCI bus circuit. The RKE module monitors the Occupant Restraint Controller messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message along with the verification that the ignition is on and the vehicle speed is zero, it will provide the "enhanced accident response feature". This feature will cause the module to unlock-all doors immediately and the instrument cluster to turn the courtesy lamps on when the vehicle reaches 0 mph. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message, and receive body style information. Two transmitters are supplied with the vehicle but a total of 4 can be programmed to the module. The horn chirp on vehicle lock command is customer programmable. To limit the amount of battery drain during storage, the IOD fuse may be removed. VEHICLE THEFT SECURITY SYSTEM When the VTSS is armed, it will monitor the ignition switch status, ajar switches for the vehicle doors and decklid. Also monitored is a decklid security switch (knockout) for the cylinder lock. If the alarm is tripped, it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2560 Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, by using the driver door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of an open decklid security switch sense circuit. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with the driver door cylinder lock. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. VEHICLE THEFT SECURITY SYSTEM (Export Only) When the VTSS is armed, it Will monitor the interior of the vehicle for movement via an intrusion sensor (if equipped), the ignition switch status, ajar switches for the vehicle doors, decklid and hood. Vehicles without an intrusion sensor will have a decklid security switch (knockout) which will also be monitored. If the alarm is tripped, it will sound the vehicles horn or a battery backed siren for vehicles equipped with the intrusion sensor, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, or by using either door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of the hood ajar circuit being shorted (hood opened) or the decklid security switch circuit being open (if equipped). Defeating the intrusion sensor feature for vehicles so equipped can be done by three additional lock request to the RKE module within 5 seconds. Disarming is done by either a RKE unlock or turning the ignition on with a valid Sentry key. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. Vehicle Communication VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2003 PL: - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio (If equipped) - CD Changer (If equipped) - Compass/Temperature Mirror (If equipped) - Remote Keyless Entry Module (If equipped) - Sentry Key Immobilizer Module (If equipped) - Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2561 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III(R) lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the diagram for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at the module, or an open battery or ground circuit to the affected Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - No response received from any module on the PCI bus (except PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2562 Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III(R) may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Airbag Indicator On Without ACM Trouble Codes Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACM TROUBLE CODES POSSIBLE CAUSES - Airbag indicator on without ACM trouble codes - Instrument cluster problems No Response From Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2565 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2566 Test 3 - 4 SYMPTOM NO RESPONSE FROM ACM POSSIBLE CAUSES - Checking for voltage at ACM - Ground circuit open - PCI bus circuit open - Airbag control module AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2567 POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2568 CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2569 Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure No Response From Radio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2570 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2571 Test 4 - 6 SYMPTOM NO RESPONSE FROM RADIO POSSIBLE CAUSES - No response from radio - Open fused ignition switch output circuit - Open fused B+ circuit - Radio ground circuit open - Open PCI bus circuit - Radio Pause/Play Switch Inoperative Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2572 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2573 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2574 - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Compass/Temperature Mirror Does Calibrate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2575 Test 1 Test 2 SYMPTOM COMPASS/TEMPERATURE MIRROR DOES CALIBRATE POSSIBLE CAUSES - Calibration procedure - Compass/temperature mirror Compass/Temperature Mirror Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2576 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2577 Test 4 - 6 SYMPTOM COMPASS/TEMPERATURE MIRROR INOPERATIVE POSSIBLE CAUSES - No response - PCI bus - compass - Fused B(+) circuit short to ground - Fused B(+) circuit open - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Ground circuit open - Compass/temperature mirror High Beam Headlamps Will Not Turn Off Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2578 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Dimmer switch high beam output circuit short to voltage - Instrument cluster - Multifunction switch High Beam Headlamps Will Not Turn On Test 1 - 4 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2579 Test 5 - 7 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Open fused B+ - Dimmer switch low beam output circuit short to ground - Dimmer switch high beam output circuit short to ground - Open fuse - Dimmer switch low beam output circuit open - Instrument cluster - Multifunction switch Low Beam Headlamps Will Not Turn Off Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2580 Test 1 - 3 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Multifunction switch - Dimmer switch low beam output circuit short to voltage - Fuse block - Instrument cluster Low Beam Headlamps Will Not Turn On Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2581 Test 1 - 4 Test 5 - 6 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Multifunction switch - Fuse block - Dimmer switch low beam output circuit open - Instrument cluster - Open fused B+ to fuse block - Fused B+ circuit short to ground - B+ circuit breaker 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2582 All Gauges Inoperative Test 1 - 4 Test 5 - 6 SYMPTOM ALL GAUGES INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2583 POSSIBLE CAUSES - No response - PCI bus - No response - PCI bus - powertrain control module - No response - PCI bus - instrument cluster - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Instrument cluster ground circuit open - Instrument cluster Any or All Gauge Pointer(s) On Wrong Side of Stop Test 1 SYMPTOM ANY OR ALL GAUGE POINTER(S) ON WRONG SIDE OF STOP POSSIBLE CAUSES - Instrument cluster Any PCI Bus Indicator Inoperative Test 1 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2584 POSSIBLE CAUSES - LED defective - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2585 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake warning indicator circuit short to ground - Red brake warning indicator driver circuit short to ground - Park brake switch - Brake fluid level switch - Instrument cluster - Powertrain control module Brake Warning Indicator Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2586 Test 4 - 7 Test 8 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2587 POSSIBLE CAUSES - Brake warning indicator circuit open - Indicator led - Brake fluid level switch - Park brake switch - Red brake warning indicator driver circuit open - Brake fluid level switch ground circuit open - Instrument cluster - Powertrain control module Front Fog Lamp Indicator Inoperative Test 1 - 2 SYMPTOM FRONT FOG LAMP INDICATOR INOPERATIVE POSSIBLE CAUSES - Front fog lamp indicator circuit open - Indicator led - Instrument cluster Fuel Gauge Inaccurate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2588 Test 1 - 2 Test 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Fuel level sensor - Intermittent condition - Instrument cluster High Beam Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2589 Test 1 - 2 SYMPTOM HIGH BEAM INDICATOR INOPERATIVE POSSIBLE CAUSES - High beam indicator circuit open - High beam indicator bulb - Instrument cluster Instrument Cluster Dimming Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2590 Test 1 - 3 SYMPTOM INSTRUMENT CLUSTER DIMMING INOPERATIVE POSSIBLE CAUSES - DTC present - Headlamp switch output circuit open - Illumination bulb - Instrument cluster Low Oil Pressure Indicator Always on Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2591 Test 1 - 3 SYMPTOM LOW OIL PRESSURE INDICATOR ALWAYS ON POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit short to ground - Powertrain control module - Instrument cluster Low Oil Pressure Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2592 Test 1 - 3 Test 4 SYMPTOM LOW OIL PRESSURE INDICATOR INOPERATIVE POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit open - Indicator led - Powertrain control module - Instrument cluster One Gauge Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2593 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE POSSIBLE CAUSES - Powertrain control module DTCs - Instrument cluster PRND or Autostick Indicator Display Inaccurate or Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2594 Test 1 - 2 SYMPTOM PRND OR AUTOSTICK INDICATOR DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - DTC present - Intermittent condition - Instrument cluster Rear Fog Lamp Indicator Inoperative - BUX Only Test 1 - 2 SYMPTOM REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY POSSIBLE CAUSES - Rear fog lamp indicator circuit open - Indicator led - Instrument cluster Seat Belt Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2595 Test 1 - 4 Test 5 SYMPTOM SEATBELT INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator led - Seat belt indicator circuit open - Seat belt switch ground open - Seat belt switch - Instrument cluster Temperature Display Inoperative or Wrong (2.0L Only) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2596 Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INOPERATIVE OR WRONG (2.0L ONLY) POSSIBLE CAUSES - DTC present in PCM - Ambient temperat1jre sensor - Compass/temperature mirror VF Display Inoperative Test 1 SYMPTOM VF DISPLAY INOPERATIVE POSSIBLE CAUSES - Instrument cluster Courtesy Lamps Inoperative - All Lamps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2597 Test 1 - 3 SYMPTOM COURTESY LAMPS INOPERATIVE - ALL LAMPS POSSIBLE CAUSES - Fused B+ circuit open - Instrument cluster - courtesy lamp open - Courtesy lamp driver circuit open - Intermittent condition Courtesy Lamps On At All Times Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2598 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2599 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2600 Test 8 - 10 SYMPTOM COURTESY LAMPS ON AT ALL TIMES POSSIBLE CAUSES - Drivers door ajar switch - Drivers door ajar switch sense wire short to ground - Remote keyless entry module - if equipped - Instrument cluster - Instrument cluster - Panel lamps dimmer signal wire short to ground - Multifunction switch - Open door ajar switch - Remote keyless entry module - if equipped - Passenger door ajar/RKE sense wire short to ground - Instrument cluster - Courtesy lamp driver circuit short to ground - Instrument cluster Illuminated Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2601 Test 1 - 2 SYMPTOM ILLUMINATED ENTRY INOPERATIVE POSSIBLE CAUSES - Courtesy lamps operational - Intermittent condition - Illuminated entry not enabled All Door Locks Inoperative Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2602 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2603 Test 8 - 13 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2604 Test 14 - 16 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Decklid release relay output wire short to ground - Fused B(+) circuit open - Fused B(+) wire short to ground - Ground circuit open - Door lock relay output circuit open - Driver door unlock relay output short to door lock relay output - Driver door unlock relay output wire short to ground - Door lock relay output wire short to ground - Door unlock relay output short to door lock relay output - Decklid release solenoid-shorted - Door unlock relay output wire short to ground - Defective fuse #14 - RKE module - B(+) short to ground - RKE module - relays open - RKE module - shorted All Doors Except Driver Fail to Lock and Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2605 Test 1 - 4 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO LOCK AND UNLOCK POSSIBLE CAUSES - RKE module - open door unlock relay output - Door unlock relay output wire open - Door lock relay output wire open - Open motors All Doors Except Driver Fail to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2606 Test 1 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO UNLOCK POSSIBLE CAUSES - Door unlock relay output circuit short to ground - Remote keyless entry module unlock relay Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTOMATIC DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Auto door locks not enabled - Door ajar status - PCM DTC's present - RKE module defective - auto locks inoperable Decklid Solenoid Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2607 Test 1 - 4 SYMPTOM DECKLID SOLENOID INOPERATIVE POSSIBLE CAUSES - Solenoid ground open - Decklid release solenoid open - Decklid release relay output wire open - RKE module - decklid relay open Doors Lockable With Key In Ignition and Driver Door Open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2608 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2609 Test 4 - 10 SYMPTOM DOORS LOCKABLE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Driver door ajar switch - open - Open driver door ajar switch sense to RKE module - Ignition switch open - Key-in ignition switch sense wire open - Open driver door ajar switch sense to cluster - Instrument cluster - key-in ignition open - Instrument cluster defective-driver door ajar open - RKE module defective-open driver door ajar Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2610 Driver Door Fails to Lock and Unlock Test 1 - 3 Test 4 SYMPTOM DRIVER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - RKE module - open driver unlock circuit - Driver door lock motor - open - Driver door lock relay output wire open - Driver door unlock relay output wire open Driver Door Fails to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2611 Test 1 SYMPTOM DRIVER DOOR FAILS TO UNLOCK POSSIBLE CAUSES - Driver door unlock relay output wire short to ground - RKE module defective - driver unlock open One Passenger Door Fails to Lock and Unlock Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2612 Test 4 - 6 SYMPTOM ONE PASSENGER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - Door lock motor open - Door unlock relay output wire open - Door lock relay output wire open - Door unlock relay output wire short to ground - Door unlock relay output short to door lock relay output - Door lock relay output wire short to ground Remote Keyless Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2613 Test 1 - 3 Test 4 - 5 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - Test RKE transmitter Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2614 - RKE transmitter - inoperative - RKE module - RKE module - receiver inoperable Alarm Trips On Its Own Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition All Doors Fail to Lock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2615 Test 1 - 4 Test 5 SYMPTOM ALL DOORS FAIL TO LOCK POSSIBLE CAUSES - Door lock relay output circuit short to ground - Decklid release relay output short to door lock relay output - Decklid release relay output short to driver door unlock relay output - Decklid release relay output short to door unlock relay output - Remote keyless entry module - unlock ground open All Locks Inoperative From A Door Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2616 Test 1 - 3 Test 4 - 6 SYMPTOM ALL LOCKS INOPERATIVE FROM A DOOR LOCK SWITCH POSSIBLE CAUSES - DTC present Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2617 - Door switch ground wire open - Door switch MUX wire short to voltage - Door switch MUX wire open - Door lock switch open - Remote keyless entry module - high voltage - Remote keyless entry module - low voltage Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH DURING ALARM POSSIBLE CAUSES - Dimmer switch low beam output circuit open - Remote keyless entry module Horn Fails to Sound When Alarm Is Tripped Test 1 SYMPTOM HORN FAILS TO SOUND DURING ALARM POSSIBLE CAUSES - Horn relay control circuit open - Remote keyless entry module Intrusion Sensor Cannot Be Disabled Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2618 Test 1 SYMPTOM INTRUSION SENSOR CANNOT BE DISABLED (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Intrusion Sensor Fails to Trip VTSS Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2619 Test 4 - 6 SYMPTOM INTRUSION SENSOR FAILS TO TRIP VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Open fused B(+) circuit - Open ground circuit - Intrusion sensor signal circuit open - Intrusion sensor signal circuit shorted to ground - Intrusion sensor - Remote keyless entry module Intrusion Sensor Repeatedly Triggers VTSS Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2620 SYMPTOM INTRUSION SENSOR REPEATEDLY TRIGGERS VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Open Driver Door Fails to Trip Alarm Test 1 - 3 SYMPTOM OPEN DRIVER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Remote keyless entry module Open Passenger Door Fails to Trip Alarm Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2621 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2622 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2623 Test 7 - 8 SYMPTOM OPEN PASSENGER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Left rear door ajar switch ground circuit open - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Right rear door ajar switch ground circuit open - Passenger door ajar/RKE sense circuit open - Left rear door ajar switch - Passenger door ajar/RKE sense circuit open - Right rear door ajar switch - Passenger door ajar/RKE circuit open - Passenger door ajar/RKE sense circuit open - Remote keyless entry module - RKE module - passenger door ajar sense Park Lamps Fail to Flash During Alarm Test 1 SYMPTOM PARK LAMPS FAIL TO FLASH DURING ALARM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2624 POSSIBLE CAUSES - Park lamp switch output circuit open - Remote keyless entry module VTSS Fails to Arm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Fails to Arm From Passenger Door Cylinder Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2625 Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM PASSENGER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Passenger door switch MUX circuit open - Passenger cylinder lock switch faulty VTSS Fails to Arm/Disarm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM/DISARM FROM DRIVER DOOR CYLINDER LOCK SWITCH Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2626 TEST NOTE This symptom is diagnosed using the test VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY). POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Indicator Fails to Flash Test 1 - 3 SYMPTOM VTSS INDICATOR FAILS TO FLASH POSSIBLE CAUSES - Remote keyless entry module - Instrument cluster - VTSS indicator driver circuit open - VTSS led open VTSS Indicator Stays On Steady During Arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2627 Test 1 - 5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2628 Test 6 - 8 SYMPTOM VTSS INDICATOR STAYS ON STEADY DURING ARMING POSSIBLE CAUSES - Decklid security switch sense circuit open (if equipped) - Decklid security switch ground circuit open (if equipped) - Decklid security switch (if equipped) - Hood ajar switch sense circuit shorted to ground (if equipped) - Hood ajar switch (if equipped) - RKE module - VTSS indicator - RKE module - hood ajar (if equipped) - RKE module - decklid security (if equipped) VTSS Siren Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2629 Test 4 - 6 SYMPTOM VTSS SIREN INOPERATIVE (EXPORT ONLY) POSSIBLE CAUSES - Siren functional test - Open fused B(+) circuit - Open ground circuit - Faulty siren - Siren control circuit open - Siren control circuit shorted to ground - Remote keyless entry module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2630 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Road Testing ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. during the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2631 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: Erase the stored codes - Place the ignition in the Run position - Wiggle the wire harness and connectors - Rotate the steering wheel from stop to stop - Recheck for active codes periodically as you work through the system. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2632 The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Glossary of Terms ABS Antilock Brake System ACM Airbag Control Module AECM Airbag Electronic Control Module (ACM) ASDM Airbag System Diagnostic Module (ACM) BUX Built-Up Export CAB Controller Antilock Brake CTM Compass/Temperature Mirror DAB Driver Airbag DLC Data Link Connector DTC Diagnostic Trouble Code EMIC Electro/Mechanical Instrument Cluster LSIACM Left SIACM NGC Next Generation Controller PAB Passenger Airbag PCI Programmable Communication Interface (Vehicle Communication Bus) PCM Powertrain Control Module PDC Power Distribution Center PWM Pulse Width Modulated RKE Remote Keyless Entry RSIACM Right SIACM SAB Side Airbag SIACM Side Impact Airbag Control Module SKIM Sentry Key Immobilizer Module SKIS Sentry Key Immobilizer System SQUIB Also Called Initiator (Located In Rear Of Airbag Module) TCM Transmission Control Module VFD Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2633 Body Control Module: Scan Tool Testing and Procedures DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2634 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. DRB III Safety Information DRB III (R) SAFETY INFORMATION WARNING: EXCEEDING THE LIMITS OF THE DRB III (R) MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLE FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS. Follow the vehicle manufacture's service specifications at all times. Do not use the DRB Ill(R) if it has been damaged. Do not use the test leads if the insulation is damaged or if metal is exposed. To avoid electrical shock, do not touch the test leads, tips, or other circuit being tested. Choose the proper range and function for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Do not exceed the limits shown in the table. Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. The circuit being tested must be protected by a 10A fuse or circuit breaker. Use the low current shunt to measure circuits up to 10A. Use the higher current clamp to measure circuits exceeding 10A. When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. When measuring current, connect the meter in series with the load. Disconnect the live test lead before disconnecting the common test lead. When using the meter function, keep the DRB III (R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2635 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read out box) Jumper Wires Ohmmeter Voltmeter Test Light 8310 Airbag Load Tool 8443 SRS Airbag System Load Tool Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2639 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2643 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2644 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2645 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2646 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 2651 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2652 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2653 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2654 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2655 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2656 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Connector Views Data Link Connector Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2662 Data Link Connector: Description and Operation Fig.4 Data Link Connector (DLC) Location The data link connector is located inside the vehicle, under the instrument panel, left of the steering column. The data link connector (diagnostic connector) links the DRB scan tool with the powertrain control module (PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling Electronic Throttle Actuator: Technical Service Bulletins Safety Systems - Inadvertent Damage/Disabling NUMBER: 08-027-04 GROUP: Electrical DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-017-01, DATED SEPTEMBER 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND YEARS. SUBJECT: Safety Systems - Vehicle Modifications/Repair MODELS: 2002 - **2003** (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2002 (BR/BE) Ram Pickup **2004 - 2005 (CS) Pacifica** 2002 - **2003** (DN) Durango **2003 - 2005 (DR/DH) Ram Pickup** **2004 - 2005 (HB) Durange 2002 - **2005** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 - **2005** (KJ) Liberty 2002 - **2004** (LH) Concorde/Intrepid/300M **2005 (LX) 300/Magnum ** **2005 (ND) Dakota** 2002 (PG) PT Cruiser (International Markets) 2002 - **2005** (PL) Neon 2002 - **2003** (PR) Prowler 2002 - **2005** (PT) Chrysler PT Cruiser 2002 - **2005** (RS) Town & Country/Caravan/Voyager 2002 - **2005** (RG) Chrysler Voyager (International Markets) 2002 (SR) Viper 2002 - **2005** (ST) Sebring Coupe/Stratus Coupe 2002 - **2005** (TJ) Wrangler **2002 - 2005 (VA) Sprinter** 2002 - **2004** (WJ) Grand Cherokee **2005 (WK) Grand Cherokee** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling > Page 2667 2002 - **2004** (WG) Grand Cherokee (International Markets) **2005 (WH) Grand Cherokee (International Markets)** **2003 - 2005 (ZB) Viper** **2004 - 2005 (ZH) Crossfire** DISCUSSION: Current DaimlerChrysler vehicles may contain any or all of the following safety Systems: driver airbags, passenger airbags, side curtain airbags, side seat airbags, seat belt pre-tensioners, anti-lock brakes, electronic throttle control, or traction control. All these systems contain multiple sophisticated sensitive electrical and mechanical components. The location and function of all safety system components must be determined before performing repairs; including accident, mechanical or electrical, or vehicle modifications such as adding an after-market sunroof. WARNING: ANY INADVERTENT SAFETY SYSTEM COMPONENT OR ASSOCIATED WIRING DAMAGE/MODIFICATION OR COMPONENT LOCATION CHANGE MAY DISABLE ANY OF THE SAFETY SYSTEMS. Refer to the appropriate vehicle Service Information to determine location and function of all safety systems before servicing vehicle. All systems should be checked for functionality after the vehicle modifications/repairs are complete. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2676 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2677 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2678 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2679 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2680 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2681 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2682 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2683 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2689 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2690 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2691 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2696 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2697 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2698 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2699 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2700 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2701 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2702 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2703 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2709 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2710 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2711 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2712 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws 4 Nm 35 In. Lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2715 Powertrain Control Module: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2716 Fig. 12 Engine (Right Front) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2717 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2718 Fig. 43 Engine (Right Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views Powertrain Control Module: Connector Views Powertrain Control Module C1 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2721 Powertrain Control Module C2 (2.0L NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2722 Powertrain Control Module C3 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2723 Powertrain Control Module C4 (EATX NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Important - Please Read Powertrain Control Module: Description and Operation Important - Please Read IMPORTANT (NGC) New for the 2003 PL is a combined Powertrain Control Module and Transmission Control Module in a single control module. This new module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Important - Please Read > Page 2726 Powertrain Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Fig.5 PCM 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, transmission, and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Ambient Air temperature Sensor - ASD Sense - Baro/Tip (Turbo) - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Important - Please Read > Page 2727 - Clutch Upstop Switch (1.6L) - Clutch Interlock - Crankshaft Position Sensor - Cruise Control Switch - Electronic Throttle Control (1.6L only) - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - J1850 - Knock Sensor (1.6, 2.0, 2.4L only) - Natural Vacuum Leak Detection (NVLD) - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Pedal Position Sensor (1.6L has 2 sensors) - Power Steering Pressure Switch - SCI Receive - Speed Control Switches - Throttle Position Sensor (1.6L has 2 TPS Sensors) - Transmission Control Relay (Switched B+) - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transmission Pressure Switches (L/R, 2/4, OD) - Transmission Range Sensor (TRS) - Transmission Oil Temperature Sensor (Integral to TRS) - Vehicle Speed Sensor (MTX-equipped models). NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp (Bus Message) - SCI Transmit - Proportional Purge Solenoid - EGR Solenoid - Electronic Throttle Control (1.6L only) - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor (2.0/2.4L) - Ignition Coils - J1850 - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Oxygen Sensors Heater Controls - Radiator Fan Relays - Speed Control Solenoids (2.0/2.4L) - Transmission Control Relay - Transmission Solenoids (LR/CC, 2/4, OD, and UD) - Transmission PRNDL Position (to Cluster) - Transmission Torque Reduction Request (Internal to PCM) - Transmission Temperature (Internal to PCM and a Bus Message) - Vehicle Speed (Manual Transmission) - 2 Electronic Throttle Control Outputs (1.6L) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Important - Please Read > Page 2728 The PCM adjusts ignition timing based on the following inputs. Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. Air conditioning sense - Battery voltage - Battery temperature - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The Auto Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off from the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Powertrain Control Module Connectors The PCM is an engine and transmission controller module all in one, if the vehicle is equipped with an automatic transmission. The PCM uses four wiring harness connectors to receive and send engine and transmission data. To ease assembly, the mating wiring harness connector is color-coded. Each module connector cavity has its own unique color identification stripe located on the outside of each connector cavity. The PCM module utilizes four wiring harness connectors as described: - Connector Cavity A is for Power & Ground (Black) - Connector Cavity B is for Engine Side (Orange) - Connector Cavity C is for Headlamp & Dash (White) - Connector Cavity D is for Transmission (Green) If equipped. NOTE: Connector Cavities A, B, C, And D must be connected prior to battery connection and ignition key on to avoid setting erroneous controller fault codes. It is also recommended that cavity A connector is made prior to any other connectors. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) An important function of the PCM is to monitor Transmission Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Important - Please Read > Page 2729 Fig.6 Example Of CVI Calculation By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRBIII Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: TRANSMISSION SHIFT SCHEDULES The PCM is programmed to allow it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Important - Please Read > Page 2730 - Software calibration level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Electronic Throttle Control (1.6L) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Pedal Position Sensor (1.6L) - Throttle position sensor - Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 2731 Powertrain Control Module: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING PCM POWER AND GROUND CIRCUITS POSSIBLE CAUSES - (A14) PCM fused B+ circuit - (A41) PCM fused ignition switch output circuit - (Z12) PCM ground circuits Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2734 Powertrain Control Module: Service and Repair Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2735 Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2736 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL Fig.4 Battery Cable 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2737 Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2738 Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2739 Powertrain Control Module: Service and Repair PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2740 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2741 Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2742 Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2743 Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Removal and Installation REMOVAL Fig.4 Battery Cable Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2744 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2745 Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2746 When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Obtaining Diagnostic Trouble Codes BULB CHECK Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 2747 Key on: Bulb illuminated until vehicle starts, as long as all once per trip (readiness) monitors completed. If monitors have not been completed, then: Key on: bulb check for about 5 to 8 seconds, lamp then flashes if once per trip (readiness) monitors have not been completed until vehicle is started, then MIL is extinguished. OBTAINING DTC'S USING DRB SCAN TOOL 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 instrument panel; near the steering column. 2. Turn the ignition switch on and access the "Read Fault" screen. 3. Record all the DTC's and "freeze frame" information shown on the DRB scan tool. 4. To erase DTC's, use the "Erase Trouble Code" data screen on the DRB scan tool. Do not erase any DTC's until problems have been investigated and repairs have been performed. Pinion Factor Setting NOTE: This procedure must be performed if the PCM/TCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM/TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain/ Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRBIII scan tool. 1. Plug the DRBIII scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRBIII scan tool screen. Quick Learn Procedure The quick learn procedure requires the use of the DRBIII scan tool. This program allows the PCM/ TCM to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain/Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBIII indicates the procedure is complete - The calculated oil temperature must be above 60° and below 200° 1. Plug the DRBIII scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRBIII to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fig.11 Fuel Pump Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 2751 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 2752 Fuel Level Sensor: Service and Repair Fig.4 Fuel Pump/Level Sensor Electrical Connector Fig.5 Wire Terminal Locking Wedge Fig.6 Removing Wires From Connector Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 2753 Fig.7 Level Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2757 Idle Air Control Motor (2.0L/2.4L Turbo) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2758 Idle Air Control (IAC) Motor: Description and Operation Fig.16 Idle Air Control Solenoid - Typical IDLE AIR CONTROL MOTOR The Idle Air Control (IAC) solenoid is mounted on the throttle body. The PCM operates the idle air control solenoid. It is an electric stepper solenoid. The PCM adjusts engine idle speed through the idle air control solenoid to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control solenoid pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC solenoid pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning and power steering). When engine rpm is above idle speed, the IAC is used for the following functions: Off-idle dashpot - Deceleration air flow control - A/C compressor load control and power steering (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) Target Idle Target idle is determined by the following inputs: Gear position - ECT Sensor - Battery voltage - Ambient/Battery Temperature Sensor - VSS - TPS - MAP Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2759 Idle Air Control (IAC) Motor: Service and Repair REMOVAL When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-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. 1. Disconnect negative cable from battery. 2. Remove electrical connector from idle air control motor. Fig.17 Servicing Idle Air Control Motor 3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the O-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new O-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB III 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 4.5 Nm (40 in. lbs.) torque. 4. Connect electrical connector to idle air control motor. 5. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2768 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2769 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2770 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2771 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2777 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2778 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2779 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2786 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2787 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Vehicle Communication Information Bus: Description and Operation Vehicle Communication COMMUNICATION The Programmable Communication Interface (PCI) data bus system is a single wire multiplex system used for vehicle communications on many DaimlerChrysler Corporation vehicles. Multiplexing is a system that enables and supports the transmission of binary encoded messages between multiple modules over a single channel or circuit. All DaimlerChrysler vehicles use this principle for communication between various microprocessor-based electronic control modules. The PCI data bus exceeds the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. The PCI bus circuit is identified as D25. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2003 PL: Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio (If equipped) - CD Changer (If equipped) - Compass/Temperature Mirror (If equipped) - Remote Keyless Entry Module (If equipped) - Sentry Key Immobilizer Module (If equipped) - Mechanical Instrument Cluster Many of the electronic control modules in a vehicle require information from the same sensing device. In the past, if information from one sensing device was required by several controllers, a wire from each controller needed to be connected in parallel to that sensor. In addition, each controller utilizing analog sensors required an Analog/Digital (A/D) converter in order to "read" these sensor inputs. Multiplexing reduces wire harness complexity, sensor current loads and controller hardware because each sensing device is connected to only one controller, which reads and distributes the sensor information to the other controllers over the data bus. Also, because each controller on the data bus can access the controller sensor inputs to every other controller on the data bus, more function and feature capabilities are possible. In addition to reducing wire harness complexity, component sensor current loads and controller hardware, multiplexing offers a diagnostic advantage. A multiplex system allows the information flowing between controllers to be monitored using a diagnostic scan tool. The DaimlerChrysler system allows an electronic control module to broadcast message data out onto the bus where all other electronic control modules can "hear" the messages that are being sent. When a module hears a message on the data bus that it requires, it relays that message to its microprocessor. Each module ignores the messages on the data bus that are being sent to other electronic control modules. Data exchange between modules is achieved by serial transmission of encoded data over a single wire broadcast network. The wire colors used for the PCI data bus circuits are yellow with a violet tracer, or violet with a yellow tracer, depending upon the application. The PCI data bus messages are carried over the bus in the form of Variable Pulse Width Modulated (VPWM) signals. The PCI data bus speed is an average 10.8 Kilo-bits per second (Kbps). By comparison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kbps. The voltage network used to transmit messages requires biasing and termination. Each module on the PCI data bus system provides its own biasing and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7-1/2 volts when modules are transmitting. Each module (also referred to as a node) terminates the bus through a terminating resistor and a terminating capacitor. There are two types of nodes on the bus. The dominant node terminates the bus through a 1 KW resistor and a 3300 pF capacitor. The Powertrain Control Module (PCM) is the only dominant node for the PCI data bus system. A standard node terminates the bus through an 11 KW resistor and a 330 pF capacitor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Vehicle Communication > Page 2790 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 volts and about 7-1/2 volts. Refer to the diagram for some typical displays. The modules bias the bus when transmitting a message. The PCI bus uses low and high voltage levels to generate signals. Low voltage is around 0 volts and the high voltage is about 7-1/2 volts. The low and high voltage levels are generated by means of variable-pulse width modulation to form signals of varying length. The Variable Pulse Width Modulation (VPWM) used in PCI bus messaging is a method in which both the state of the bus and the width of the pulse are used to encode bit information. A "zero" bit is defined as a short low pulse or a long high pulse. A "one" bit is defined as a long low pulse or a short high pulse. A low (passive) state on the bus does not necessarily mean a zero bit. It also depends upon pulse width. If the width is short, it stands for a zero bit. If the width is long, it stands for a one bit. Similarly, a high (active) state does not necessarily mean a one bit. This too depends upon pulse width. If the width is short, it stands for a one bit. If the width is long, it stands for a zero bit. In the case where there are successive zero or one data bits, both the state of the bus and the width of the pulse are changed alternately. This encoding scheme is used for two reasons. First, this ensures that only one symbol per transition and one transition per symbol exists. On each transition, every transmitting module must decode the symbol on the bus and begin timing of the next symbol. Since timing of the next symbol begins with the last transition detected on the bus, all of the modules are re-synchronized with each symbol. This ensures that there are no accumulated timing errors during PCI data bus communication. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Vehicle Communication > Page 2791 The second reason for this encoding scheme is to guarantee that the zero bit is the dominant bit on the bus. When two modules are transmitting simultaneously on the bus, there must be some form of arbitration to determine which module will gain control. A data collision occurs when two modules are transmitting different messages at the same time. When a module is transmitting on the bus, it is reading the bus at the same time to ensure message integrity. When a collision is detected, the module that transmitted the one bit stops sending messages over the bus until the bus becomes idle. Each module is capable of transmitting and receiving data simultaneously. The typical PCI bus message has the following four components: Message Header - One to three bytes in length. The header contains information identifying the message type and length, message priority, target module(s) and sending module. - Data Byte(s) - This is the actual message that is being sent. - Cyclic Redundancy Check (CRC) Byte This byte is used to detect errors during a message transmission. - In-Frame Response (IFR) byte(s) - If a response is required from the target module (s), it can be sent during this frame. This function is described in greater detail in the following paragraph. The IFR consists of one or more bytes, which are transmitted during a message. If the sending module requires information to be received immediately, the target module (s) can send data over the bus during the original message. This allows the sending module to receive time-critical information without having to wait for the target module to access the bus. After the IFR is received, the sending module broadcasts an End of Frame (EOF) message and releases control of the bus. The PCI data bus can be monitored using the DRB III scan tool. It is possible, however, for the bus to pass all DRB III tests and still be faulty if the voltage parameters are all within the specified range and false messages are being sent. PCI Bus Failure Modes The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at the module, or an open battery or ground circuit to the affected Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - No response received from any module on the PCI bus (except PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller # 8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Vehicle Communication > Page 2792 Information Bus: Description and Operation Programmable Communication Interface (PCI) Bus PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS The Programmable Communication Interface Multiplex system (PCI Bus) consist of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its ground as the bus reference. The wiring is a minimum 20 gage wire. Various modules exchange information through a communications port called the PCI Bus. The Powertrain Control Module (PCM) transmits the Malfunction Indicator Lamp (Check Engine) ON/OFF signal and engine RPM on the PCI Bus. The PCM receives the Air Conditioning select input, transaxle gear position inputs over the PCI Bus. The PCM also receives the air conditioning evaporator temperature signal from the PCI Bus. The following components access or send information on the PCI Bus. Instrument Panel - Body Control Module - Airbag System Diagnostic Module - Full ATC Display Head (if equipped) - ABS Module - Transmission Control Module - Powertrain Control Module - Travel Module - SKIM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Information Bus: Symptom Related Diagnostic Procedures VEHICLE COMMUNICATION Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III(R) may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Refer to Body Control System. See: Body Control Module Refer to Computers and Control Systems. See: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2798 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2802 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Malfunction Indicator Light ................................................................................................................... ............................................................... LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Application and ID > Page 2806 Malfunction Indicator Lamp: Description and Operation Refer to the Instrument Cluster for more information. The PCM supplies the malfunction indicator (check engine) lamp ON/OFF signal to the instrument panel through the PCI Bus. The PCI Bus is a communications port. Various modules use the PCI Bus to exchange information. The Check Engine lamp comes ON each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Malfunction Indicator Lamp (MIL) stays ON continuously when the PCM has entered a Limp-In mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM compensates for the failure of certain components that send incorrect signals. The PCM substitutes for the incorrect signals with inputs from other sensors. If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the MIL. At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger the MIL (Check Engine Lamp) refer to the On-Board Diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Fig. 15 Engine (Top) (2.0L) - LHD Fig. 48 Engine (Top) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2810 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2811 Manifold Absolute Pressure Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2812 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.23 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezo-resistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key ON is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key ON the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2813 The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2814 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL Fig.24 MAP Sensor The MAP sensor attaches to the intake manifold plenum. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION The MAP sensor attaches to the intake manifold plenum. 1. Insert sensor into intake manifold while making sure not to damage O-ring seal. 2. Tighten mounting screws to 4.5 Nm (40 in. lbs.) torque for plastic manifold. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2818 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2823 Oxygen Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2824 Fig. 13 Engine (Left Rear) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2825 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2826 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2827 Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2828 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2829 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - 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 1/1. - 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2830 Oxygen Sensor: Description and Operation Fig.30 Types Of O2 Sensors Fig.27 Upstream Heated Oxygen Sensor 1/1 O2 SENSOR The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2831 Fig.28 Downstream Heated Oxygen Sensor 1/2 Fig.29 Heated Oxygen Sensor Systems The downstream heated oxygen sensor threads into the system depending on emission package. Federal package the O2S is mounted after the catalytic convertor, LEV package the O2S is mounted mid catalytic convertor, ULEV package is mounted between the catalytic convertor. A single sensor ground is used for all O2 sensors (2 sensors on 4 cyl. vehicles and 4 sensors on 6 cyl. vehicles). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2832 monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM uses pulse width modulation to control the ground side of the heater to regulate the temperature on 4 cyl. upstream O2 heater only. All other 4 cyl. and 6 cyl. O2 heaters do not use pulse width modulation. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2) O2 Sensor Oxygen Sensor: Service and Repair Downstream (1/2) O2 Sensor REMOVAL Fig.32 Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 1. Raise vehicle. 2. Disconnect electrical connector from harness. 3. Disconnect sensor electrical harness from clips along body. Fig.33 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 5. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect sensor electrical harness from clips along body Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2) O2 Sensor > Page 2835 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2) O2 Sensor > Page 2836 Oxygen Sensor: Service and Repair Upstream (1/1) O2 Sensor REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig.31 Upstream Heated Oxygen Sensor Removal/Installation 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 4. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Plug sensor connector. 3. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2837 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Remover/Installer - C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 2842 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 2843 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 2844 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2845 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Body Control Module: Electrical Diagrams Airbag System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Audio System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 CD Changer Compass/Temperature Mirror Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 Exterior Lighting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 Instrument Cluster Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 Interior Lighting Power Door Locks/RKE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 Vehicle Communication Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2885 Body Control Module: Vehicle Damage Warnings Electrical Testing 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description Identification Of System The vehicle systems that are part of the "body" system are: - Airbag System - Audio - Compass/Temperature Mirror - Instrument Cluster - Interior Lighting - Power Door Locks/Remote Keyless Entry - Vehicle Communications - Vehicle Theft Security System System Description The body system on the 2003 PL consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Vehicle Communication See: Functional Operation/Vehicle Communication of this general information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2888 Body Control Module: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. DRIVER AIRBAG (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation, The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2889 PASSENGER AIRBAG (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). WARNING: REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) They are located on the left and right B-post. The SIACM perform self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ACM once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned on. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. SEAT AIRBAGS The Left and Right seat airbag modules are located in the outboard end of the front seat backs. The airbag module contains a bag, an inflator (a small canister of highly compressed argon gas) and a mounting bracket. The seat airbag module cannot be repaired and must be replaced if deployed or in any way damaged. When supplied with the proper electrical signal the inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. NOTE: It will be necessary to remove the seat back trim to gain access to the seat airbag module connector when diagnosing the seat airbag system. WARNING: THE SEAT AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SPECIAL TOOLS Some airbag diagnostic tests use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2890 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: * Erase the stored codes * Place the ignition in the Run position * Wiggle the wire harness and connectors * Rotate the steering wheel from stop to stop * Recheck for active codes periodically as you work through the system. Audio System AUDIO SYSTEM The audio system on the 2003 PL consists of a radio that communicates over the PCI bus. The speakers are located in the instrument panel, the front doors and the rear "D" pillars. The instrument panel speakers are a tweeter type speaker for high frequency. The front door speakers are a woofer/midrange type speaker. The rear "D" pillar speakers are a full range type speaker. If one of the speaker circuits experiences a short, the other speakers on that output channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which the DRB III(R) can display. The in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect , such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in the chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2891 disc in that chamber. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Compass/Temperature Mirror COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2892 Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2893 magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2894 If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Exterior Lighting EXTERIOR LIGHTING The Headlamps are controlled by the Instrument Cluster. The Instrument Cluster is also referred to as a "Smart Cluster". It receives and sends messages to other modules through the PCI BUS circuit. The Headlamps are wired through the cluster and then go to the Fuse Block to the lamps. Each Headlamp has an independent fuse located in the Fuse Block. For vehicles equipped with Daytime Running Lamps, the DRL Module is integrated with the Instrument Cluster. Interior Lighting INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. Some of the features that it controls are the courtesy lamps, chime, and all instrument illumination. It receives and sends messages to other modules via the PCI bus circuit. The front turn signals are wired through the cluster and then go to the front lamps. For vehicles equipped with Daytime Running Lamps, the DRL module is built into the cluster. Power Door Locks/Remote Keyless Entry REMOTE KEYLESS ENTRY MODULE The Remote Keyless Entry module controls the Power Door Locks and the Vehicle Theft Security System (VTSS). It also wakes up the Instrument Cluster to turn on the illuminated entry when it senses a signal from the RKE transmitter. The module communicates with other modules via the PCI bus circuit. The RKE module monitors the Occupant Restraint Controller messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message along with the verification that the ignition is on and the vehicle speed is zero, it will provide the "enhanced accident response feature". This feature will cause the module to unlock-all doors immediately and the instrument cluster to turn the courtesy lamps on when the vehicle reaches 0 mph. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message, and receive body style information. Two transmitters are supplied with the vehicle but a total of 4 can be programmed to the module. The horn chirp on vehicle lock command is customer programmable. To limit the amount of battery drain during storage, the IOD fuse may be removed. VEHICLE THEFT SECURITY SYSTEM When the VTSS is armed, it will monitor the ignition switch status, ajar switches for the vehicle doors and decklid. Also monitored is a decklid security switch (knockout) for the cylinder lock. If the alarm is tripped, it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2895 Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, by using the driver door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of an open decklid security switch sense circuit. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with the driver door cylinder lock. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. VEHICLE THEFT SECURITY SYSTEM (Export Only) When the VTSS is armed, it Will monitor the interior of the vehicle for movement via an intrusion sensor (if equipped), the ignition switch status, ajar switches for the vehicle doors, decklid and hood. Vehicles without an intrusion sensor will have a decklid security switch (knockout) which will also be monitored. If the alarm is tripped, it will sound the vehicles horn or a battery backed siren for vehicles equipped with the intrusion sensor, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, or by using either door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of the hood ajar circuit being shorted (hood opened) or the decklid security switch circuit being open (if equipped). Defeating the intrusion sensor feature for vehicles so equipped can be done by three additional lock request to the RKE module within 5 seconds. Disarming is done by either a RKE unlock or turning the ignition on with a valid Sentry key. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. Vehicle Communication VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2003 PL: - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio (If equipped) - CD Changer (If equipped) - Compass/Temperature Mirror (If equipped) - Remote Keyless Entry Module (If equipped) - Sentry Key Immobilizer Module (If equipped) - Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2896 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III(R) lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the diagram for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at the module, or an open battery or ground circuit to the affected Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - No response received from any module on the PCI bus (except PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2897 Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III(R) may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Airbag Indicator On Without ACM Trouble Codes Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACM TROUBLE CODES POSSIBLE CAUSES - Airbag indicator on without ACM trouble codes - Instrument cluster problems No Response From Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2900 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2901 Test 3 - 4 SYMPTOM NO RESPONSE FROM ACM POSSIBLE CAUSES - Checking for voltage at ACM - Ground circuit open - PCI bus circuit open - Airbag control module AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2902 POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2903 CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2904 Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure No Response From Radio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2905 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2906 Test 4 - 6 SYMPTOM NO RESPONSE FROM RADIO POSSIBLE CAUSES - No response from radio - Open fused ignition switch output circuit - Open fused B+ circuit - Radio ground circuit open - Open PCI bus circuit - Radio Pause/Play Switch Inoperative Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2907 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2908 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2909 - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Compass/Temperature Mirror Does Calibrate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2910 Test 1 Test 2 SYMPTOM COMPASS/TEMPERATURE MIRROR DOES CALIBRATE POSSIBLE CAUSES - Calibration procedure - Compass/temperature mirror Compass/Temperature Mirror Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2911 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2912 Test 4 - 6 SYMPTOM COMPASS/TEMPERATURE MIRROR INOPERATIVE POSSIBLE CAUSES - No response - PCI bus - compass - Fused B(+) circuit short to ground - Fused B(+) circuit open - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Ground circuit open - Compass/temperature mirror High Beam Headlamps Will Not Turn Off Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2913 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Dimmer switch high beam output circuit short to voltage - Instrument cluster - Multifunction switch High Beam Headlamps Will Not Turn On Test 1 - 4 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2914 Test 5 - 7 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Open fused B+ - Dimmer switch low beam output circuit short to ground - Dimmer switch high beam output circuit short to ground - Open fuse - Dimmer switch low beam output circuit open - Instrument cluster - Multifunction switch Low Beam Headlamps Will Not Turn Off Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2915 Test 1 - 3 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Multifunction switch - Dimmer switch low beam output circuit short to voltage - Fuse block - Instrument cluster Low Beam Headlamps Will Not Turn On Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2916 Test 1 - 4 Test 5 - 6 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Multifunction switch - Fuse block - Dimmer switch low beam output circuit open - Instrument cluster - Open fused B+ to fuse block - Fused B+ circuit short to ground - B+ circuit breaker 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2917 All Gauges Inoperative Test 1 - 4 Test 5 - 6 SYMPTOM ALL GAUGES INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2918 POSSIBLE CAUSES - No response - PCI bus - No response - PCI bus - powertrain control module - No response - PCI bus - instrument cluster - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Instrument cluster ground circuit open - Instrument cluster Any or All Gauge Pointer(s) On Wrong Side of Stop Test 1 SYMPTOM ANY OR ALL GAUGE POINTER(S) ON WRONG SIDE OF STOP POSSIBLE CAUSES - Instrument cluster Any PCI Bus Indicator Inoperative Test 1 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2919 POSSIBLE CAUSES - LED defective - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2920 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake warning indicator circuit short to ground - Red brake warning indicator driver circuit short to ground - Park brake switch - Brake fluid level switch - Instrument cluster - Powertrain control module Brake Warning Indicator Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2921 Test 4 - 7 Test 8 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2922 POSSIBLE CAUSES - Brake warning indicator circuit open - Indicator led - Brake fluid level switch - Park brake switch - Red brake warning indicator driver circuit open - Brake fluid level switch ground circuit open - Instrument cluster - Powertrain control module Front Fog Lamp Indicator Inoperative Test 1 - 2 SYMPTOM FRONT FOG LAMP INDICATOR INOPERATIVE POSSIBLE CAUSES - Front fog lamp indicator circuit open - Indicator led - Instrument cluster Fuel Gauge Inaccurate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2923 Test 1 - 2 Test 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Fuel level sensor - Intermittent condition - Instrument cluster High Beam Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2924 Test 1 - 2 SYMPTOM HIGH BEAM INDICATOR INOPERATIVE POSSIBLE CAUSES - High beam indicator circuit open - High beam indicator bulb - Instrument cluster Instrument Cluster Dimming Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2925 Test 1 - 3 SYMPTOM INSTRUMENT CLUSTER DIMMING INOPERATIVE POSSIBLE CAUSES - DTC present - Headlamp switch output circuit open - Illumination bulb - Instrument cluster Low Oil Pressure Indicator Always on Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2926 Test 1 - 3 SYMPTOM LOW OIL PRESSURE INDICATOR ALWAYS ON POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit short to ground - Powertrain control module - Instrument cluster Low Oil Pressure Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2927 Test 1 - 3 Test 4 SYMPTOM LOW OIL PRESSURE INDICATOR INOPERATIVE POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit open - Indicator led - Powertrain control module - Instrument cluster One Gauge Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2928 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE POSSIBLE CAUSES - Powertrain control module DTCs - Instrument cluster PRND or Autostick Indicator Display Inaccurate or Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2929 Test 1 - 2 SYMPTOM PRND OR AUTOSTICK INDICATOR DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - DTC present - Intermittent condition - Instrument cluster Rear Fog Lamp Indicator Inoperative - BUX Only Test 1 - 2 SYMPTOM REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY POSSIBLE CAUSES - Rear fog lamp indicator circuit open - Indicator led - Instrument cluster Seat Belt Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2930 Test 1 - 4 Test 5 SYMPTOM SEATBELT INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator led - Seat belt indicator circuit open - Seat belt switch ground open - Seat belt switch - Instrument cluster Temperature Display Inoperative or Wrong (2.0L Only) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2931 Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INOPERATIVE OR WRONG (2.0L ONLY) POSSIBLE CAUSES - DTC present in PCM - Ambient temperat1jre sensor - Compass/temperature mirror VF Display Inoperative Test 1 SYMPTOM VF DISPLAY INOPERATIVE POSSIBLE CAUSES - Instrument cluster Courtesy Lamps Inoperative - All Lamps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2932 Test 1 - 3 SYMPTOM COURTESY LAMPS INOPERATIVE - ALL LAMPS POSSIBLE CAUSES - Fused B+ circuit open - Instrument cluster - courtesy lamp open - Courtesy lamp driver circuit open - Intermittent condition Courtesy Lamps On At All Times Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2933 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2934 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2935 Test 8 - 10 SYMPTOM COURTESY LAMPS ON AT ALL TIMES POSSIBLE CAUSES - Drivers door ajar switch - Drivers door ajar switch sense wire short to ground - Remote keyless entry module - if equipped - Instrument cluster - Instrument cluster - Panel lamps dimmer signal wire short to ground - Multifunction switch - Open door ajar switch - Remote keyless entry module - if equipped - Passenger door ajar/RKE sense wire short to ground - Instrument cluster - Courtesy lamp driver circuit short to ground - Instrument cluster Illuminated Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2936 Test 1 - 2 SYMPTOM ILLUMINATED ENTRY INOPERATIVE POSSIBLE CAUSES - Courtesy lamps operational - Intermittent condition - Illuminated entry not enabled All Door Locks Inoperative Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2937 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2938 Test 8 - 13 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2939 Test 14 - 16 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Decklid release relay output wire short to ground - Fused B(+) circuit open - Fused B(+) wire short to ground - Ground circuit open - Door lock relay output circuit open - Driver door unlock relay output short to door lock relay output - Driver door unlock relay output wire short to ground - Door lock relay output wire short to ground - Door unlock relay output short to door lock relay output - Decklid release solenoid-shorted - Door unlock relay output wire short to ground - Defective fuse #14 - RKE module - B(+) short to ground - RKE module - relays open - RKE module - shorted All Doors Except Driver Fail to Lock and Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2940 Test 1 - 4 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO LOCK AND UNLOCK POSSIBLE CAUSES - RKE module - open door unlock relay output - Door unlock relay output wire open - Door lock relay output wire open - Open motors All Doors Except Driver Fail to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2941 Test 1 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO UNLOCK POSSIBLE CAUSES - Door unlock relay output circuit short to ground - Remote keyless entry module unlock relay Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTOMATIC DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Auto door locks not enabled - Door ajar status - PCM DTC's present - RKE module defective - auto locks inoperable Decklid Solenoid Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2942 Test 1 - 4 SYMPTOM DECKLID SOLENOID INOPERATIVE POSSIBLE CAUSES - Solenoid ground open - Decklid release solenoid open - Decklid release relay output wire open - RKE module - decklid relay open Doors Lockable With Key In Ignition and Driver Door Open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2943 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2944 Test 4 - 10 SYMPTOM DOORS LOCKABLE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Driver door ajar switch - open - Open driver door ajar switch sense to RKE module - Ignition switch open - Key-in ignition switch sense wire open - Open driver door ajar switch sense to cluster - Instrument cluster - key-in ignition open - Instrument cluster defective-driver door ajar open - RKE module defective-open driver door ajar Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2945 Driver Door Fails to Lock and Unlock Test 1 - 3 Test 4 SYMPTOM DRIVER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - RKE module - open driver unlock circuit - Driver door lock motor - open - Driver door lock relay output wire open - Driver door unlock relay output wire open Driver Door Fails to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2946 Test 1 SYMPTOM DRIVER DOOR FAILS TO UNLOCK POSSIBLE CAUSES - Driver door unlock relay output wire short to ground - RKE module defective - driver unlock open One Passenger Door Fails to Lock and Unlock Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2947 Test 4 - 6 SYMPTOM ONE PASSENGER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - Door lock motor open - Door unlock relay output wire open - Door lock relay output wire open - Door unlock relay output wire short to ground - Door unlock relay output short to door lock relay output - Door lock relay output wire short to ground Remote Keyless Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2948 Test 1 - 3 Test 4 - 5 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - Test RKE transmitter Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2949 - RKE transmitter - inoperative - RKE module - RKE module - receiver inoperable Alarm Trips On Its Own Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition All Doors Fail to Lock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2950 Test 1 - 4 Test 5 SYMPTOM ALL DOORS FAIL TO LOCK POSSIBLE CAUSES - Door lock relay output circuit short to ground - Decklid release relay output short to door lock relay output - Decklid release relay output short to driver door unlock relay output - Decklid release relay output short to door unlock relay output - Remote keyless entry module - unlock ground open All Locks Inoperative From A Door Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2951 Test 1 - 3 Test 4 - 6 SYMPTOM ALL LOCKS INOPERATIVE FROM A DOOR LOCK SWITCH POSSIBLE CAUSES - DTC present Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2952 - Door switch ground wire open - Door switch MUX wire short to voltage - Door switch MUX wire open - Door lock switch open - Remote keyless entry module - high voltage - Remote keyless entry module - low voltage Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH DURING ALARM POSSIBLE CAUSES - Dimmer switch low beam output circuit open - Remote keyless entry module Horn Fails to Sound When Alarm Is Tripped Test 1 SYMPTOM HORN FAILS TO SOUND DURING ALARM POSSIBLE CAUSES - Horn relay control circuit open - Remote keyless entry module Intrusion Sensor Cannot Be Disabled Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2953 Test 1 SYMPTOM INTRUSION SENSOR CANNOT BE DISABLED (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Intrusion Sensor Fails to Trip VTSS Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2954 Test 4 - 6 SYMPTOM INTRUSION SENSOR FAILS TO TRIP VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Open fused B(+) circuit - Open ground circuit - Intrusion sensor signal circuit open - Intrusion sensor signal circuit shorted to ground - Intrusion sensor - Remote keyless entry module Intrusion Sensor Repeatedly Triggers VTSS Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2955 SYMPTOM INTRUSION SENSOR REPEATEDLY TRIGGERS VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Open Driver Door Fails to Trip Alarm Test 1 - 3 SYMPTOM OPEN DRIVER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Remote keyless entry module Open Passenger Door Fails to Trip Alarm Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2956 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2957 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2958 Test 7 - 8 SYMPTOM OPEN PASSENGER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Left rear door ajar switch ground circuit open - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Right rear door ajar switch ground circuit open - Passenger door ajar/RKE sense circuit open - Left rear door ajar switch - Passenger door ajar/RKE sense circuit open - Right rear door ajar switch - Passenger door ajar/RKE circuit open - Passenger door ajar/RKE sense circuit open - Remote keyless entry module - RKE module - passenger door ajar sense Park Lamps Fail to Flash During Alarm Test 1 SYMPTOM PARK LAMPS FAIL TO FLASH DURING ALARM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2959 POSSIBLE CAUSES - Park lamp switch output circuit open - Remote keyless entry module VTSS Fails to Arm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Fails to Arm From Passenger Door Cylinder Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2960 Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM PASSENGER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Passenger door switch MUX circuit open - Passenger cylinder lock switch faulty VTSS Fails to Arm/Disarm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM/DISARM FROM DRIVER DOOR CYLINDER LOCK SWITCH Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2961 TEST NOTE This symptom is diagnosed using the test VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY). POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Indicator Fails to Flash Test 1 - 3 SYMPTOM VTSS INDICATOR FAILS TO FLASH POSSIBLE CAUSES - Remote keyless entry module - Instrument cluster - VTSS indicator driver circuit open - VTSS led open VTSS Indicator Stays On Steady During Arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2962 Test 1 - 5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2963 Test 6 - 8 SYMPTOM VTSS INDICATOR STAYS ON STEADY DURING ARMING POSSIBLE CAUSES - Decklid security switch sense circuit open (if equipped) - Decklid security switch ground circuit open (if equipped) - Decklid security switch (if equipped) - Hood ajar switch sense circuit shorted to ground (if equipped) - Hood ajar switch (if equipped) - RKE module - VTSS indicator - RKE module - hood ajar (if equipped) - RKE module - decklid security (if equipped) VTSS Siren Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2964 Test 4 - 6 SYMPTOM VTSS SIREN INOPERATIVE (EXPORT ONLY) POSSIBLE CAUSES - Siren functional test - Open fused B(+) circuit - Open ground circuit - Faulty siren - Siren control circuit open - Siren control circuit shorted to ground - Remote keyless entry module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2965 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Road Testing ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. during the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2966 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: Erase the stored codes - Place the ignition in the Run position - Wiggle the wire harness and connectors - Rotate the steering wheel from stop to stop - Recheck for active codes periodically as you work through the system. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2967 The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Glossary of Terms ABS Antilock Brake System ACM Airbag Control Module AECM Airbag Electronic Control Module (ACM) ASDM Airbag System Diagnostic Module (ACM) BUX Built-Up Export CAB Controller Antilock Brake CTM Compass/Temperature Mirror DAB Driver Airbag DLC Data Link Connector DTC Diagnostic Trouble Code EMIC Electro/Mechanical Instrument Cluster LSIACM Left SIACM NGC Next Generation Controller PAB Passenger Airbag PCI Programmable Communication Interface (Vehicle Communication Bus) PCM Powertrain Control Module PDC Power Distribution Center PWM Pulse Width Modulated RKE Remote Keyless Entry RSIACM Right SIACM SAB Side Airbag SIACM Side Impact Airbag Control Module SKIM Sentry Key Immobilizer Module SKIS Sentry Key Immobilizer System SQUIB Also Called Initiator (Located In Rear Of Airbag Module) TCM Transmission Control Module VFD Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2968 Body Control Module: Scan Tool Testing and Procedures DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2969 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. DRB III Safety Information DRB III (R) SAFETY INFORMATION WARNING: EXCEEDING THE LIMITS OF THE DRB III (R) MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLE FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS. Follow the vehicle manufacture's service specifications at all times. Do not use the DRB Ill(R) if it has been damaged. Do not use the test leads if the insulation is damaged or if metal is exposed. To avoid electrical shock, do not touch the test leads, tips, or other circuit being tested. Choose the proper range and function for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Do not exceed the limits shown in the table. Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. The circuit being tested must be protected by a 10A fuse or circuit breaker. Use the low current shunt to measure circuits up to 10A. Use the higher current clamp to measure circuits exceeding 10A. When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. When measuring current, connect the meter in series with the load. Disconnect the live test lead before disconnecting the common test lead. When using the meter function, keep the DRB III (R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2970 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read out box) Jumper Wires Ohmmeter Voltmeter Test Light 8310 Airbag Load Tool 8443 SRS Airbag System Load Tool Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2979 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2980 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2981 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2982 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2983 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2984 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2985 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > C08 > Mar > 03 > Campaign - Powertrain Control Module Replacement > Page 2986 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2992 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2993 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2994 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement Technical Service Bulletin # C08 Date: 030301 Campaign - Powertrain Control Module Replacement March 2003 Dealer Service Instructions for: Customer Satisfaction Notification No. C08 Replace Powertrain Control Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 02-025 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2003 (LH) Dodge Intrepid, Chrysler Concorde and 300M (PT) Chrysler PT Cruiser (PL) Dodge Neon (JR) Dodge Stratus Sedan NOTE: This notification applies only to certain vehicles equipped with an automatic transmission (Sales Code DGB) built through October 4, 2002 (MDH 1004XX) IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process The Powertrain Control Module (PCM) on about 550 of the above vehicles may contain a computer driver chip that could fail. Driver chip failure may cause the Malfunction Indicator Light (MIL) to illuminate and cause the transmission to shift into 2nd gear (default limp-in mode) The PCM must be replaced. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which PCM is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The PCM for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 2999 > Entering the VIN into the VIP System (sales code information) along with the table (all dealers): Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the PCM 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. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and DealerConnect/MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3000 All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are 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 and then type "ORDC08". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Replace PCM - LH Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the speed control servo and set it aside. 3. Remove the washer fluid bottle filler neck bolt and set the filler neck aside. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3001 4. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 1). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 1). 6. Install the new PCM. Tighten the mounting bolts to 35 in-lbs (4 N.m) (Figure 1). 7. Connect the four (4) PCM electrical connectors (Figure 1). 8. Install the washer fluid bottle filler neck. Tighten the bolt securely. 9. Install the speed control servo. Tighten the servo bracket bolts securely. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. B. Replace PCM - PL Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the air cleaner assembly and set it aside. 3. Disconnect the four (4) PCM electrical connectors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3002 4. Remove the three (3) PCM bracket fasteners (Figure 2) and then remove the PCM and bracket assembly. 5. Remove the three (3) PCM bolts, then remove the PCM and discard it (Figure 2). 6. Install the new PCM (Figure 2). Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly. Tighten the fasteners to 95 in-lbs (10.7 Nm). 8. Connect the four (4) PCM electrical connectors. Attach the wiring harness clip to the PCM bracket. 9. Install the air cleaner assembly. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. C. Replace PCM - PT Vehicles 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 3). 3. Disconnect the two (2) wiring harness clips from the PCM bracket Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3003 4. Remove the four (4) PCM mounting bracket screws and then remove the PCM and mounting bracket assembly (Figure 3). 5. Remove the three (3) PCM bolts, then remove the PCM and discard it. 6. Install the new PCM onto the mounting bracket. Tighten the mounting bolts to 105 in-lbs (11.8 Nm). 7. Install the PCM and bracket assembly (Figure 3). Tighten the mounting bolts to 95 in-lbs (10.7 N.m). 8. Connect the four (4) PCM electrical connectors (Figure 3). 9. Attach the wiring harness clips to the PCM bracket. 10. Connect the negative battery cable. 11. Continue with Section E - PCM/Vehicle Data Set-up. D. Replace PCM - JR Vehicles 1. Disconnect the negative battery cable (Figure 4). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Disconnect the four (4) PCM electrical connectors and set the wiring harness aside (Figure 4). 3. Remove the two (2) PCM bracket fasteners and then remove the PCM and bracket assembly (Figure 4). 4. Remove the three (3) PCM bolts, then remove the PCM and discard it. 5. Install the new PCM on the bracket. Tighten the mounting bolts to 35 in-lbs (4 N.m). 6. Install the PCM and bracket assembly (Figure 4). Tighten the fasteners to 35 in-lbs (4 N.m). 7. Connect the four (4) PCM electrical connectors. 8. Connect the negative battery cable. 9. Continue with Section E - PCM/Vehicle Data Set-up. E. PCM/Vehicle Data Set-Up 1. Connect the DRB III(R) to the data link connector located under the instrument panel. Turn the ignition key to the "ON" position. 2. With the ignition switch in the "ON" position, determine if the vehicle is equipped with a SKIM module by using the DRB III and selecting from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3004 the menu screen: a. Select # 1 - "DRB III Standalone" from Main Menu screen. b. Select # 1 - "1998 - 2004 Diagnostics" from Standalone Main Menu screen. c. Select # 1 - "All (Except Below)" from 1998 - 2004 Diagnostics screen. d. Select # 8 - "System Monitor" from Select System screen. e. Select # 3 - "J1850 Module Scan" from Select Monitor screen and then press ENTER to continue and note if the vehicle is equipped with SKIM. > If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with Step 3. This information is available from the original selling invoice, the Dial VIP System, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. WARNING: Failure to use the SKIM PIN number to transfer the secret key code data from the SKIM module will cause a no-start condition. > If the vehicle is not equipped with SKIM then continue with Step 3. f. Press PAGE BACK. 3. Press PAGE BACK to return to the Select System screen. 4. Select # 1 - "Engine" from Select System screen. 5 Press ENTER to continue. 6. Press the RIGHT ARROW key to go to Page 2 of 2. 7. Select # 1 - "Miscellaneous". 8 Select # 3 - "Check VIN". 9. Press ENTER to program the VIN. If the vehicle is equipped with SKIM: a. Press ENTER to continue. b. Press ENTER to continue again. c. Enter the vehicle 4-digit PIN. d. Press ENTER to continue. e. Press ENTER to continue again. f. Press ENTER to continue again. g. Press ENTER to update VIN. h. Press ENTER to continue. i. Press ENTER to transfer secret key data. j. Press ENTER to continue. k. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER. l. Press any key to continue. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3005 If the vehicle is NOT equipped with SKIM: a. Enter the 17-digit VIN. b. Press ENTER to continue. c. Press PAGEBACK. 10. Select # 1 - "Miscellaneous" 11. Select # 1 - "Check PCM Odometer" 12. Press YES if the vehicle has LESS than 50 miles on the odometer or press NO if the vehicle has MORE than 50 miles on the odometer. 13. Enter current odometer reading and then press ENTER. 14. Cycle ignition key to "OFF" position and then back to "ON" position and then press ENTER 15. Press PAGE BACK. 16. Press PAGE BACK again. 17. Select # 2 - "Transmission" 18. Select # 1 - "Transmission Module". 19. Select # 9 - "Miscellaneous". 20. Select # 3 - "Pinion Factor". 21. Press any key to continue. 22. Select the correct tire size for the vehicle and then press ENTER. 23 Verify the selected tire size and then press PAGE BACK to exit. 24. Select # 6 - "Quicklearn" and then follow the instructions displayed on the DRB III screen. 25. Disconnect the DRB III. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > C08 > Mar > 03 > Campaign Powertrain Control Module Replacement > Page 3006 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3012 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3013 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3014 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3015 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws 4 Nm 35 In. Lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 3018 Powertrain Control Module: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 3019 Fig. 12 Engine (Right Front) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 3020 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 3021 Fig. 43 Engine (Right Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views Powertrain Control Module: Connector Views Powertrain Control Module C1 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 3024 Powertrain Control Module C2 (2.0L NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 3025 Powertrain Control Module C3 (NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Connector Views > Page 3026 Powertrain Control Module C4 (EATX NGC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read Powertrain Control Module: Description and Operation Important - Please Read IMPORTANT (NGC) New for the 2003 PL is a combined Powertrain Control Module and Transmission Control Module in a single control module. This new module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 3029 Powertrain Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Fig.5 PCM 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, transmission, and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Ambient Air temperature Sensor - ASD Sense - Baro/Tip (Turbo) - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 3030 - Clutch Upstop Switch (1.6L) - Clutch Interlock - Crankshaft Position Sensor - Cruise Control Switch - Electronic Throttle Control (1.6L only) - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - J1850 - Knock Sensor (1.6, 2.0, 2.4L only) - Natural Vacuum Leak Detection (NVLD) - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Pedal Position Sensor (1.6L has 2 sensors) - Power Steering Pressure Switch - SCI Receive - Speed Control Switches - Throttle Position Sensor (1.6L has 2 TPS Sensors) - Transmission Control Relay (Switched B+) - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transmission Pressure Switches (L/R, 2/4, OD) - Transmission Range Sensor (TRS) - Transmission Oil Temperature Sensor (Integral to TRS) - Vehicle Speed Sensor (MTX-equipped models). NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp (Bus Message) - SCI Transmit - Proportional Purge Solenoid - EGR Solenoid - Electronic Throttle Control (1.6L only) - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor (2.0/2.4L) - Ignition Coils - J1850 - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Oxygen Sensors Heater Controls - Radiator Fan Relays - Speed Control Solenoids (2.0/2.4L) - Transmission Control Relay - Transmission Solenoids (LR/CC, 2/4, OD, and UD) - Transmission PRNDL Position (to Cluster) - Transmission Torque Reduction Request (Internal to PCM) - Transmission Temperature (Internal to PCM and a Bus Message) - Vehicle Speed (Manual Transmission) - 2 Electronic Throttle Control Outputs (1.6L) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 3031 The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. Air conditioning sense - Battery voltage - Battery temperature - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Pedal Position Sensor (1.6L has 2 sensors) - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The Auto Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off from the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Powertrain Control Module Connectors The PCM is an engine and transmission controller module all in one, if the vehicle is equipped with an automatic transmission. The PCM uses four wiring harness connectors to receive and send engine and transmission data. To ease assembly, the mating wiring harness connector is color-coded. Each module connector cavity has its own unique color identification stripe located on the outside of each connector cavity. The PCM module utilizes four wiring harness connectors as described: - Connector Cavity A is for Power & Ground (Black) - Connector Cavity B is for Engine Side (Orange) - Connector Cavity C is for Headlamp & Dash (White) - Connector Cavity D is for Transmission (Green) If equipped. NOTE: Connector Cavities A, B, C, And D must be connected prior to battery connection and ignition key on to avoid setting erroneous controller fault codes. It is also recommended that cavity A connector is made prior to any other connectors. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) An important function of the PCM is to monitor Transmission Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 3032 Fig.6 Example Of CVI Calculation By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRBIII Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: TRANSMISSION SHIFT SCHEDULES The PCM is programmed to allow it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Important - Please Read > Page 3033 - Software calibration level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Electronic Throttle Control (1.6L) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Pedal Position Sensor (1.6L) - Throttle position sensor - Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Page 3034 Powertrain Control Module: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING PCM POWER AND GROUND CIRCUITS POSSIBLE CAUSES - (A14) PCM fused B+ circuit - (A41) PCM fused ignition switch output circuit - (Z12) PCM ground circuits Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3037 Powertrain Control Module: Service and Repair Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3038 Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3039 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL Fig.4 Battery Cable 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3040 Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3041 Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3042 Powertrain Control Module: Service and Repair PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3043 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3044 Powertrain Control Module: Service and Repair Programming the Powertrain Control Module IMPORTANT NOTE Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal failure to components (i.e. 12-volt pull-ups, drivers and ground sensors). These failures are difficult to detect when a double fault has occurred and only one DTC has set. NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. The SKIS Secret Key is an I.D. code that is unique to each SKIS. This code is programmed and stored in the SKIM, engine controller and transponder chip (ignition key). When replacing the PCM it is necessary to program the secret key into the PCM. NOTE: After replacing the PCM, you must program pinion factor. 1. Turn the ignition on (transmission in Park/Neutral). 2. Use the DRBIII and select THEFT ALARM. SKIM then MISCELLANEOUS. 3. Select PCM REPLACED. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: If three attempts are made to enter the secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the run position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 5. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). Powertrain Control Module Replacement REMOVAL - 2.0L 1. Disconnect the negative battery cable. Fig.9 Air Box Relocated 2. Remove and relocate the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3045 Fig.10 Connectors Installed 3. Unlock and disconnect the electrical connectors at the PCM. Fig.11 Wiring Harness 4. Remove the wiring harness clip from the PCM bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3046 Fig.12 PCM And Bracket 5. Remove the mounting bolts from the bottom of the PCM bracket. 6. Remove the nut. 7. Remove the assembly, PCM and bracket. INSTALLATION - 2.0L 1. Install the assembly, PCM and bracket. 2. Loose install the mounting nut. 3. Install the mounting bolts to the bottom of the PCM bracket. 4. Tighten the mounting nut, tighten to. 5. Install the wiring harness clip to the PCM bracket. NOTE: The electrical connector for the PCM are COLOR Coded. 6. Connect the electrical connectors and lock at the PCM. 7. Install the air cleaner box, refer to the Engine/Air Intake/Air Cleaner Housing for more information. 8. Connect the negative battery cable. Removal and Installation REMOVAL Fig.4 Battery Cable Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3047 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box. Fig.5 Powertrain Control Module (PCM) 3. Remove the gray and black connector from the PCM. Fig.6 PCM Wiring Bracket 4. Remove the harness clip bracket from PCM bracket. 5. Remove the nut from the upper bracket mount. 6. Raise vehicle and support on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3048 Fig.7 Lower Mounting Bolts 7. Remove 2 lower bracket bolts. Fig.8 PCM Bracket Screws 8. Remove 4 screws from bracket and remove bracket from PCM. INSTALLATION 1. Install bracket to PCM and tighten screws. 2. Install PCM and bracket to body and tighten the 2 lower bolts. 3. Lower vehicle. 4. Install upper bracket nut and tighten. 5. Clip in wiring harness bracket. 6. Install gray and black connectors to the PCM. 7. Install the air cleaner box, refer to the air cleaner box. 8. Connect the negative battery cable. PCM/Skim Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3049 When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Obtaining Diagnostic Trouble Codes BULB CHECK Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Programming the Powertrain Control Module > Page 3050 Key on: Bulb illuminated until vehicle starts, as long as all once per trip (readiness) monitors completed. If monitors have not been completed, then: Key on: bulb check for about 5 to 8 seconds, lamp then flashes if once per trip (readiness) monitors have not been completed until vehicle is started, then MIL is extinguished. OBTAINING DTC'S USING DRB SCAN TOOL 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 instrument panel; near the steering column. 2. Turn the ignition switch on and access the "Read Fault" screen. 3. Record all the DTC's and "freeze frame" information shown on the DRB scan tool. 4. To erase DTC's, use the "Erase Trouble Code" data screen on the DRB scan tool. Do not erase any DTC's until problems have been investigated and repairs have been performed. Pinion Factor Setting NOTE: This procedure must be performed if the PCM/TCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM/TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain/ Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRBIII scan tool. 1. Plug the DRBIII scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRBIII scan tool screen. Quick Learn Procedure The quick learn procedure requires the use of the DRBIII scan tool. This program allows the PCM/ TCM to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain/Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBIII indicates the procedure is complete - The calculated oil temperature must be above 60° and below 200° 1. Plug the DRBIII scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRBIII to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3054 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 3060 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 3061 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3062 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3063 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3067 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 18 Nm 13.2 Ft. Lbs. 165 In. Lbs Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 3071 Engine Coolant Temperature (ECT) Sensor: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 3072 Engine Coolant Temperature Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 3073 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor threads into the rear of the cylinder head, next to the camshaft position sensor. New sensors have sealant applied to the threads. The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air-fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus for temperature gauge operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 3074 Engine Coolant Temperature (ECT) Sensor: Service and Repair 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 sensor to 18 Nm (165 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 3079 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3080 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3081 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3082 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3083 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3084 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fig.11 Fuel Pump Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3088 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3089 Fuel Level Sensor: Service and Repair Fig.4 Fuel Pump/Level Sensor Electrical Connector Fig.5 Wire Terminal Locking Wedge Fig.6 Removing Wires From Connector Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3090 Fig.7 Level Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3095 Intake Air Temperature (IAT) Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3096 Fig. 8 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3097 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3098 Fig. 48 Left Side Engine - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3099 Inlet Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3100 Intake Air Temperature (IAT) Sensor: Description and Operation Fig.18 Inlet Air Temperature Sensor INLET AIR TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct. The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3101 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the inlet air temperature sensor 3. Remove the air cleaner lid. 4. Disconnect the inlet air tube from the throttle body. 5. Remove inlet air tube from air cleaner lid. INSTALLATION 1. Install inlet air tube to air cleaner lid and tighten clamp. 2. Install inlet air tube to throttle body and tighten clamp. 3. Install air cleaner lid to air cleaner box. 4. Connect the inlet air temperature sensor electrical connector. 5. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3105 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Fig. 15 Engine (Top) (2.0L) - LHD Fig. 48 Engine (Top) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3109 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3110 Manifold Absolute Pressure Sensor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3111 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.23 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezo-resistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key ON is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key ON the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3112 The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3113 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL Fig.24 MAP Sensor The MAP sensor attaches to the intake manifold plenum. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION The MAP sensor attaches to the intake manifold plenum. 1. Insert sensor into intake manifold while making sure not to damage O-ring seal. 2. Tighten mounting screws to 4.5 Nm (40 in. lbs.) torque for plastic manifold. 3. Attach electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3117 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3122 Oxygen Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3123 Fig. 13 Engine (Left Rear) (2.0L) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3124 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3125 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3126 Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3127 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3128 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - 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 1/1. - 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3129 Oxygen Sensor: Description and Operation Fig.30 Types Of O2 Sensors Fig.27 Upstream Heated Oxygen Sensor 1/1 O2 SENSOR The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3130 Fig.28 Downstream Heated Oxygen Sensor 1/2 Fig.29 Heated Oxygen Sensor Systems The downstream heated oxygen sensor threads into the system depending on emission package. Federal package the O2S is mounted after the catalytic convertor, LEV package the O2S is mounted mid catalytic convertor, ULEV package is mounted between the catalytic convertor. A single sensor ground is used for all O2 sensors (2 sensors on 4 cyl. vehicles and 4 sensors on 6 cyl. vehicles). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3131 monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM uses pulse width modulation to control the ground side of the heater to regulate the temperature on 4 cyl. upstream O2 heater only. All other 4 cyl. and 6 cyl. O2 heaters do not use pulse width modulation. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2) O2 Sensor Oxygen Sensor: Service and Repair Downstream (1/2) O2 Sensor REMOVAL Fig.32 Downstream Heated Oxygen Sensor The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 1. Raise vehicle. 2. Disconnect electrical connector from harness. 3. Disconnect sensor electrical harness from clips along body. Fig.33 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 5. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect sensor electrical harness from clips along body Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2) O2 Sensor > Page 3134 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2) O2 Sensor > Page 3135 Oxygen Sensor: Service and Repair Upstream (1/1) O2 Sensor REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig.31 Upstream Heated Oxygen Sensor Removal/Installation 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 4. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. INSTALLATION New sensors have compound on the threads and do not require an additional coating. 1. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Plug sensor connector. 3. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3136 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Remover/Installer - C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 3141 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 3142 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 3143 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3144 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3149 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3150 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3151 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3152 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3153 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3159 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3160 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3161 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3162 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3163 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3164 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3165 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Connector Views Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3175 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3176 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3177 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3178 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3179 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3185 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3186 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3187 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3188 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3189 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3190 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3191 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Connector Views Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Catalytic converter to exhaust manifold flange-fasteners 250 in.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 3201 Catalytic Converter: Description and Operation DESCRIPTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 3202 An under-floor catalytic converter is used on all three converter packages; EURO, Low Emission Vehicle (LEV), and the High Output engine. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. An exhaust flex-joint coupling secures the catalytic converter to the exhaust manifold by using four fasteners and a gasket for sealing. The flex-joint is serviced with the catalytic converter. CAUTION: When servicing the catalytic converter, care must be exercised not to dent or bend the flexjoint. Should this occur, the flex-joint will eventually fail and require the catalytic converter to be replaced. Do not allow the exhaust system to hang unsupported. If the isolators are removed and the catalytic converter is still attached to the exhaust manifold, failure to the flex joint will result. OPERATION The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases. Specifically, HC and CO emissions are converted into water (H20) and Carbon Dioxide (C02). Oxides of Nitrogen (NOx) are converted into elemental Nitrogen (N) and water. The three-way catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1. The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a high oxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to convert the gases. This is known as catalyst "punch through." Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of catalyst performance. Refer to the appropriate Diagnostic Information for diagnosis of a catalyst related Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 3203 Diagnostic Trouble Code (DTC). The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders, if exhaust system is equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. This deterioration of the catalyst core can result in excessively high emission levels, noise complaints, and exhaust restrictions. Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system/floor pan temperatures because of no air movement under the vehicle. The flex joint allows flexing as the engine moves, preventing breakage that could occur from the back-and-forth motion of a transverse mounted engine. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements) and between model years. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 3204 Catalytic Converter: Service and Repair REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. 1. Remove muffler and exhaust pipe. 2. Disconnect the downstream oxygen sensor electrical connector. 3. Remove the exhaust manifold support bracket (LEV only). 4. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle. 5. Remove and discard the flange gasket. NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used. INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. Check catalytic converter for a flow restriction. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 3205 NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the Appropriate Diagnostic Information for test procedures. INSTALLATION NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked. 1. Assemble catalytic converter to exhaust manifold connection. Use a new flange gasket. 2. Install exhaust manifold support bracket (LEV only). Tighten M10 bolt to 54 Nm (40 ft. lbs.), M12 bolt to 95 Nm (70 ft. lbs.), and nut to 28 Nm (250 in. lbs.). 3. Install bolt attaching manifold support bracket to the heat shield (NLEV only). Tighten bolt to 28 Nm (250 in. lbs.). 4. Assemble muffler and exhaust pipe to catalytic converter. Install muffler and pipe support isolators to the underbody 5. Tighten the catalytic converter to exhaust manifold fasteners to 28 Nm (250 in. lbs.). 6. Working from the front of the system; align each component to maintain position and proper clearance with under body components. Tighten all slip joint band clamps to 47 Nm (35 ft. lbs.). CAUTION: Exhaust band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced. 7. If removed, install downstream oxygen sensor. 8. Connect downstream oxygen sensor electrical connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3210 EVAP/Purge Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3211 Canister Purge Solenoid: Description and Operation EVAP/PURGE SOLENOID All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. 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. Fig.1 Proportional Purge Solenoid The proportional purge solenoid operates at a frequency of 200 Hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3212 Canister Purge Solenoid: Service and Repair REMOVAL Fig.2 Proportional Purge Solenoid Valve The solenoid attaches to a bracket near the steering gear . The solenoid will not operate unless it is installed correctly. The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. 1. Raise vehicle and support. 2. Disconnect electrical connector from solenoid. 3. Disconnect vacuum tubes from solenoid. 4. Remove solenoid from bracket. INSTALLATION 1. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. 4. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3216 Evaporative Emission Control Canister: Description and Operation VAPOR CANISTER Fig.16 EVAP Canister The vacuum and vapor tubes connect to the top of the canister. All vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The Powertrain Control Module (PCM) purges the canister through the proportional purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. Purge Free Cells Purge-free memory cells are used to identify the fuel vapor content of the evaporative canister. Since the evaporative canister is not purged 100% of the time, the PCM stores information about the evaporative canister's vapor content in a memory cell. The purge-free cells are constructed similar to certain purge-normal cells. The purge-free cells can be monitored by the DRB III Scan Tool. The only difference between the purge-free cells and normal adaptive cells is that in purge-free, the purge is completely turned OFF. This gives the PCM the ability to compare purge and purge-free operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3217 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Raise vehicle and support. Fig.17 EVAP Canister 3. Disconnect the hoses from the EVAP canister. Fig.18 EVAP 4. Remove 1 nut from the bracket of the EVAP canister. 5. Remove EVAP canister from bracket. INSTALLATION 1. Install EVAP canister to Bracket 2. Install 2 nuts to EVAP canister and bracket and tighten nuts to 6.7 Nm (60 in. lbs.). 3. Connect hoses. 4. Install EVAP canister and bracket to vehicle and tighten nut 22.4 Nm (250 in. lbs.). 5. Lower vehicle. 6. Connect negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3221 Natural Vacuum Leak Detection Assembly (2.0L Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations Leak Detection Pump (If Equipped) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3225 Natural Vacuum Leak Detection Assembly (2.0L Except Export/2.4L Turbo) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3226 Leak Detection Pump: Description and Operation OPERATION The Natural Vacuum Leak Detection (NVLD) system is the next generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller (NGC). This new system replaces the leak detection pump as the method of evaporative system leak detection. This is to detect a leak equivalent to a 0.020" (0.5 mm) hole. This system has the capability to detect holes of this size very dependably. The basic leak detection theory employed with NVLD is the "Gas Law". This is to say that the pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel will only see this effect if it is indeed sealed. Even small leaks will allow the pressure in the vessel to come to equilibrium with the ambient pressure. In addition to the detection of very small leaks, this system has the capability of detecting medium as well as large evaporative system leaks. A vent valve seals the canister vent during engine off conditions. If the vapor system has a leak of less than the failure threshold, the evaporative system will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak determination by this diagnostic. When the vacuum in the system exceeds about 1" H2O (0.25 KPA), a vacuum switch closes. The switch closure sends a signal to the NGC. The NGC, via appropriate logic strategies (described below), utilizes the switch signal, or lack thereof, to make a determination of whether a leak is present. The NVLD device is designed with a normally open vacuum switch, a normally closed solenoid, and a seal, which is actuated by both the solenoid and a diaphragm. The NVLD is located on the atmospheric vent side of the canister. The NVLD assembly may be mounted on top of the canister outlet, or in-line between the canister and atmospheric vent filter. The normally open vacuum switch will close with about 1" H2O (0.25 KPA) vacuum in the evaporative system. The diaphragm actuates the switch. This is above the opening point of the fuel inlet check valve in the fill tube so cap off leaks can be detected. Submerged fill systems must have recirculation lines that do not have the in-line normally closed check valve that protects the system from failed nozzle liquid ingestion, in order to detect cap off conditions. The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system during the engine off condition. If vacuum in the evaporative system exceeds 3" to 6" H2O (0.75 to 1.5 KPA), the valve will be pulled off the seat, opening the seal. This will protect the system from excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative. The solenoid actuates the valve to unseal the canister vent while the engine is running. It also will be used to close the vent during the medium and large leak tests and during the purge flow check. This solenoid requires initial 1.5 amps of current to pull the valve open but after 100 ms. will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle. Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system. The device will "blow off" at about 0.5" H2O (0.12 KPA) pressure to permit the venting of vapors during refueling. An added benefit to this is that it will also allow the tank to "breathe" during increasing temperatures, thus limiting the pressure in the tank to this low level. This is beneficial because the induced vacuum during a subsequent declining temperature will achieve the switch closed (pass threshold) sooner than if the tank had to decay from a built up pressure. The device itself has 3 wires: Switch sense, solenoid driver and ground. The NGC utilizes a high-side driver to energize and duty-cycle the solenoid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3227 Leak Detection Pump: Service and Repair REMOVAL 1. Raise and support vehicle on a hoist. 2. Push locking tab on electrical connector to unlock and remove connector. 3. loosen the sway bar bracket to remove the pump bracket. 4. Remove pump and bracket as an assembly 5. Disconnect lines from LDP. 6. Remove filter. 7. Remove pump from bracket. INSTALLATION 1. Install pump to bracket and tighten bolts to 1.2 Nm (10.6 in. lbs.). 2. Install filter and tighten to 2.8 Nm (25 in. lbs.). NOTE: The LDP bracket must be between the rail and sway bar bracket. 3. Install pump and bracket assembly to body and tighten front bolt to 11.7 Nm (105 in. lbs.). 4. Install sway bar bracket bolt and tighten bolts to 33.8 Nm (25 ft. lbs.). 5. Before installing hoses to LDP, make sure they are not cracked or split. If a hose leaks, it will cause the Check Engine Lamp to illuminate. Connect lines to the LDP. 6. Install electrical connector to pump and push locking tab to lock. 7. Lower vehicle 8. Use the DRB III scan tool, verify proper operation of LDP. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations Fig.10 PCV System - 2.0L Fig. 6 Engine OFF Or Engine Backfire No Vapor Flow This valve is screwed into the engine valve cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3232 Positive Crankcase Ventilation Valve: Description and Operation Fig.10 PCV System - 2.0L PCV Valve a plastic valve in the engine valve cover. Fig.11 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.12 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. In this position there is minimal vapor flow through the valve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3233 Fig.13 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE ............................................................................................................................... ......................................... 400 ± 34 kPa (58 ± 5 psi) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3238 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3239 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3240 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3244 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair REMOVAL CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. 1. Remove throttle cable cover. Fig.1 Throttle Cable 2. Hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam (Fig. 1). Fig.2 Accelerator Pedal And Throttle Cable 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. 2). 4. Pull back the carpet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 3251 Fig.3 Accelerator Pedal 5. Working from inside the vehicle, remove nuts from accelerator pedal attaching studs (Fig. 3) Remove assembly from vehicle. INSTALLATION CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in. lbs.) 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. 4. Install the throttle cable cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 AIR CLEANER ELEMENT REMOVAL 1. Remove 5 screws from air cleaner element box lid. 2. Remove lid from air cleaner box. 3. Pull air cleaner up and out of air cleaner box. INSTALLATION 1. Install air cleaner element on to throttle body and push towards the throttle body and past lip in air cleaner box bottom (Fig. 10). 2. Install lid and tighten screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Capacity Specifications Fuel: Capacity Specifications Fuel Capacity Fuel Capacity 12.5 gal (47.5 L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Capacity Specifications > Page 3260 Fuel: Fluid Type Specifications Fuel Octane Rating Fuel Octane Rating 91 Octane Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Fuel Filler Cap Fuel Filler Cap: Description and Operation Fuel Filler Cap The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It's purpose is to retain vapors and fuel in the fuel tank. The fuel filler cap incorporates a two-way relief valve that is closed to atmosphere during normal operating conditions. The relief valve is calibrated to open when a pressure of 17 kPa (2.5 psi) or vacuum of 2 kPa (0.6 in.Hg) occurs in the fuel tank. When the pressure or vacuum is relieved, the valve returns to the normally closed position. CAUTION: Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel system component. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Fuel Filler Cap > Page 3265 Fuel Filler Cap: Description and Operation Fuel Cap Lock Cylinder Fig.32 Locking Fuel Cap FUEL CAP LOCK CYLINDER Some vehicles are equipped with a locking fuel filler neck cap tethered to the fuel tank filler neck (Fig. 32). This limited factory installed locking fuel cap utilizes the standard vehicle key to lock and unlock the fuel cap from the fuel tank filler tube. A locking fuel filler neck cap is utilized to prevent refueling the vehicle with the ignition ON, theft or contamination of the vehicle fuel supply The standard vehicle ignition key is used to lock or unlock the fuel filler cap. By inserting and rotating the ignition key to the right, unlocks the cap. Rotating to the left, locks the cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 3266 Fuel Filler Cap: Service and Repair FUEL CAP LOCK CYLINDER REMOVAL Fig.33 Removing Retaining Ring 1. Using a flat-bladed pry tool, pry fuel cap retaining ring free from cap assembly (Fig. 33). Fig.34 Step 2 2. Remove threaded portion of cap assembly (Fig. 34). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 3267 Fig.35 Removing Fuel Cap Tether 3. Remove lock cylinder engagement collar and tether (Fig. 35). Fig.36 Depressing Lock Cylinder Retaining Clip Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 3268 Fig.37 Lock Cylinder Removed 4. Depress the spring loaded lock cylinder retaining clip (Fig. 36) and remove the lock cylinder from the cap (Fig. 37). INSTALLATION 1. Install the keyed lock cylinder in cap. 2. Position lock cylinder engagement collar and tether (Fig. 35). 3. Position threaded portion of cap (Fig. 34). 4. Snap retaining ring in position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3273 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Return fuel pump relay to PDC. 6. One or more Diagnostic Trouble Codes (DTCs) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3278 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3279 Fuel Injector: Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3280 Fuel Injector: Diagrams Fuel Injector No. 1 Fuel Injector No. 2 Fuel Injector No. 3 Fuel Injector No. 4 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3281 Fuel Injector: Description and Operation Fig.9 Fuel Injector Location - Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 9). Fig.10 Fuel Injector - Typical The fuel injectors are 12 volt electrical solenoids (Fig. 10). 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 or two streams. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not interchangeable between engines. The PCM provides battery voltage to each injector through the ASD relay. Injector operation is controlled by a ground path provided for each injector by the PCM. Injector on-time (pulse-width) is variable, and is determined by the PCM processing all the data previously discussed to obtain the optimum injector pulse width for each operating condition. The pulse width is controlled by the duration of the ground path provided. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3282 Fuel Injector: Service and Repair Fig.11 Fuel Injectors Fig.12 Remove/Install Injector Connector REMOVAL - INJECTOR CONNECTOR 1. Disconnect electrical connectors at the fuel injectors (Fig. 11). To remove connector refer to (Fig. 12). Pull the red colored slider away from injector (1). While pulling the slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, make note of wiring location before removal. REMOVAL 1. Disconnect negative cable from battery. 2. Release fuel system pressure. Refer to Fuel System Pressure Release procedure. 3. Disconnect fuel supply tube from rail. Refer to Quick-Connect Fittings in the Fuel Delivery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3283 Fig.15 Crankshaft Sensor Location 4. Disconnect electrical connectors from fuel injectors (Fig. 13), refer to the fuel injector connector section for electrical connector removal. 5. Remove fuel rail mounting screws. 6. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. INSTALLATION 1. Apply a light coating of clean engine oil to the upper O-ring. 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the O-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 ± 3 Nm (200 ± 30 in. lbs.). 6. Attach electrical connectors to fuel injectors, refer to the fuel injector connector section for electrical connector installation. 7. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Standard Procedure - Quick-Connect Fittings Fuel Line Coupler: Service and Repair Standard Procedure - Quick-Connect Fittings STANDARD PROCEDURE - QUICK-CONNECT FITTINGS REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. 1. Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect negative cable from battery or auxiliary jumper terminal. 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. INSTALLATION 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 quickconnect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. 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. Fig.29 Plastic Quick-Connect Fitting/Fuel Tube Connection 4. The plastic 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. 29). Do not rely upon the audible click to confirm a secure connection. 5. Connect negative cable to battery or auxiliary jumper terminal. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for several minutes, until the test is stopped, or until the ignition switch is turned to the OFF position. 6. Use the DRBIII scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Standard Procedure - Quick-Connect Fittings > Page 3288 Fuel Line Coupler: Service and Repair Standard Procedure - Two-Tab Type Fitting STANDARD PROCEDURE - TWO-TAB TYPE FITTING Fig.30 Typical Two-Tab Type Quick-Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting (Fig. 30). These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. 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. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE IN THIS GROUP. DISCONNECTION / CONNECTION 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure in this group. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly 4. To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 30) against sides of quick- connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. 5. Inspect quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15 - 30 lbs.). 9. Connect negative cable to battery or auxiliary jumper terminal. 10. Use the DRB III scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Standard Procedure - Quick-Connect Fittings > Page 3289 Fuel Line Coupler: Service and Repair Standard Procedure - Plastic Retainer Ring Type Fitting STANDARD PROCEDURE - PLASTIC RETAINER RING TYPE FITTING Fig.31 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 31) usually black in color. 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. 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. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. DISCONNECTION / CONNECTION 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (Fig. 31). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. 5. After disconnection, plastic retainer ring will remain with 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 quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 8. Insert quick-connect fitting into 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 or auxiliary jumper terminal 11. Use the DRB III scan tool ASD Fuel System Test to pressurize the fuel system Check for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Pressure Regulator Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator FUEL FILTER/FUEL PRESSURE 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. Fig.1 Side View - Filter/Regulator It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly (Fig. 1) Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of approximately 400 ± 34 kPa (58 ± 5 psi) at the fuel injectors. 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 58 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Pressure Regulator > Page 3295 Fig.11 Fuel Pump Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3296 Fuel Pressure Regulator: Service and Repair FUEL PRESSURE REGULATOR REPLACEMENT REMOVAL 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. 1. Refer to Fuel System Pressure Release in the Fuel Delivery System. The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Fuel pump module removal is not necessary. 2. Raise vehicle on hoist. 3. Disconnect fuel supply line at the Filter/Regulator nipple (refer to Quick Connect Fittings). Fig.9 Locking Spring Tab 4. Depress locking spring tab on side of Fuel/Regulator (Fig. 9) and rotate 90° counter-clockwise and pull out. NOTE: Make sure that the upper and lower O-rings are on the Filter/Regulator assembly. INSTALLATION Lightly lubricate the O-rings with engine oil. 1. Insert Filter/Regulator into the opening in the fuel pump module, align the two hold down tabs with the flange. Fig.10 Spring Tab In Locating Slot Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3297 2. While applying downward pressure, rotate the Filter/Regulator clockwise until the the spring tab engages the locating slot (Fig. 10). 3. Connect the fuel line to the Filter/Regulator. 4. Lower vehicle from hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE ............................................................................................................................... ......................................... 400 ± 34 kPa (58 ± 5 psi) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3302 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3303 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3304 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3308 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3309 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump 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 the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair INLET FILTER REPLACEMENT REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Fig.28 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 28). 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation Fig.15 Fuel Rail The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold (Fig. 15). 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. Refer to Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System. The fuel rail is not repairable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3316 Fuel Rail: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Release fuel system pressure. Refer to Fuel System Pressure Release procedure. 3. Disconnect fuel supply tube from rail. Refer to Quick-Connect Fittings in the Fuel Delivery. Fig.16 Fuel Rail And Injectors 4. Disconnect electrical connectors from fuel injectors (Fig. 16), refer to the fuel injector connector section for electrical connector removal. 5. Remove fuel rail mounting screws. 6. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. Fig.17 Fuel Injector Retainer 7. Remove fuel injector retainer (Fig. 17). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3317 Fig.18 Fuel Injector O-Rings 8. Pull injector out of fuel rail. Replace fuel injector O-rings (Fig. 18). INSTALLATION 1. Apply a light coating of clean engine oil to the upper O-ring. 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the O-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 ± 3 Nm (200 ± 30 in. lbs.). 6. Attach electrical connectors to fuel injectors, refer to the fuel injector connector section for electrical connector installation. 7. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair Fuel Filler Neck: Service and Repair REMOVAL 1. Loosen fuel filler tube cap. Fig.26 Fuel Filler Neck 2. Remove fuel filler neck screws (Fig. 26). 3. Raise and support vehicle. 4. Remove splash shield from wheel well. 5. Disconnect fuel fill vapor tube. 6. Disconnect fuel filler tube from fuel tank. 7. Remove groundstrap from body. Fig.28 Remove Filler Neck 8. Remove filler neck (Fig. 27). INSTALLATION 1. Install filler tube. 2. Install fuel filler neck screws and plastic filler cup. 3. Connect fuel fill vapor tube. 4. Connect fuel filler tube to fuel tank. Tighten clamp. 5. Connect ground strap to body. 6. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Page 3322 7. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3326 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor (track). The resistor track is used to send electrical signals to the instrument cluster for fuel gauge operation and are then transmitted to the engine controller for OBDII emission requirements. For Fuel Gauge Operation: As fuel level increases, the float and arm move up. This increases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This decreases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the instrument cluster, the instrument cluster will transmit the data across the J1850 bus circuits to the PCM. For OBD II Emission Requirements: The voltage signal is sent to the instrument cluster to indicate fuel level. The cluster transmits the fuel level to the PCM where it is used to prevent a false setting of misfire and fuel system monitor trouble codes. This occurs if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3327 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDING UNIT/SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig.4 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 4). Fig.5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge (Fig. 5). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3328 Fig.6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 6). 4. Push level sensor signal and ground terminals out of the connector (Fig. 6). Fig.7 Level Sensor 5. Slide level sensor wires through opening fuel pump module (Fig. 7). 6. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 7). Ensure tab at bottom of sensor locks in place. 4. 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. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Module <--> [Fuel Tank Unit] > Component Information > Diagrams Fuel Pump Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 3335 Idle Air Control Motor (2.0L/2.4L Turbo) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 3336 Idle Air Control (IAC) Motor: Description and Operation Fig.16 Idle Air Control Solenoid - Typical IDLE AIR CONTROL MOTOR The Idle Air Control (IAC) solenoid is mounted on the throttle body. The PCM operates the idle air control solenoid. It is an electric stepper solenoid. The PCM adjusts engine idle speed through the idle air control solenoid to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control solenoid pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC solenoid pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning and power steering). When engine rpm is above idle speed, the IAC is used for the following functions: Off-idle dashpot - Deceleration air flow control - A/C compressor load control and power steering (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) Target Idle Target idle is determined by the following inputs: Gear position - ECT Sensor - Battery voltage - Ambient/Battery Temperature Sensor - VSS - TPS - MAP Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 3337 Idle Air Control (IAC) Motor: Service and Repair REMOVAL When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-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. 1. Disconnect negative cable from battery. 2. Remove electrical connector from idle air control motor. Fig.17 Servicing Idle Air Control Motor 3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the O-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new O-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB III 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 4.5 Nm (40 in. lbs.) torque. 4. Connect electrical connector to idle air control motor. 5. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3341 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3346 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3347 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump 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 the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3351 Automatic Shut Down Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Variable Induction Control Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Variable Induction Control Relay > Component Information > Locations > Page 3355 Manifold Tuning Valve Relay (RT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3361 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3362 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3363 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3364 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3365 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3369 Throttle Body: Service and Repair REMOVAL Fig.34 Battery Negative Cable 1. Disconnect the negative battery cable (Fig. 34). 2. Remove the air cleaner box cover. Fig.35 Air Cleaner Element 3. Remove the air cleaner element (Fig. 35). Pull up on element, past the lip in the box, to remove it from the air cleaner box. 4 Disconnect the electrical connection at the throttle body. 5. Loosen the clamp on throttle body outlet hose. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3370 Fig.36 Throttle Body Bolts 6 Remove the bolts holding the throttle body to the air cleaner box (Fig. 36). Fig.37 Disconnecting Throttle Cable Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3371 Fig.38 Transmission Kickdown Cable Connector 7. Remove cable s from throttle body cam (Fig. 37) and (Fig. 38). INSTALLATION 1. Install cable s into throttle cam and clip cable s into throttle cable bracket. 2. Install throttle body onto air cleaner box. Tighten mounting bolts. 3. Install and tighten the clamp on throttle body outlet hose. 4. Connect the electrical connectors to the throttle body. 5 Install the air cleaner element, make sure that the element is past the lip on the air cleaner box. 6. Install the air cleaner box cover and tighten the screws. 7. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair REMOVAL 1. Remove throttle cable cover or engine cover, if equipped. Fig.45 Throttle Body Cables Attachment In Throttle Body Fig.46 Disconnecting Throttle Cable 2. Working from the engine compartment, remove throttle cable from throttle body cam (Fig. 45) and (Fig. 46). 3. Lift the retaining tabs on the cable and slide cable out of bracket. 4. From inside the vehicle, hold the throttle pedal up and remove the cable retainer and cable from upper end of pedal shaft (Fig. 2). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3375 Fig.47 Retainer Clip 5. Remove retainer clip from throttle cable and grommet at the dashpanel (Fig. 47). 6. From the engine compartment, pull the throttle cable and grommet out of the dash panel. INSTALLATION 1. Install grommet into dashpanel. 2. From the engine compartment, push the housing end fitting into the dashpanel grommet. 3. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp (Fig. 46). 4. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 5. Install throttle cable cover. 6 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. 47). 7 Install cable retainer clip (Fig. 47). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3380 Throttle Position Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3381 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3382 Throttle Position Senor (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3383 Throttle Position Sensor: Description and Operation Fig.48 Throttle Position Sensor And Idle DESCRIPTION The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) 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. OPERATION 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 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 from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3384 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Loosen the clamp for the air duct at the throttle body. 3. Remove the mounting bolt and nut for the air cleaner box. 4. Pull the air cleaner box and throttle body up to access the throttle position sensor. 5. Remove the throttle position sensor. INSTALLATION 1. Install the throttle position sensor. 2. Locate the air cleaner box and throttle body and tighten the mounting bolt and nut. 3. Install the air duct hose and tighten the clamp. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Relay > Component Information > Locations > Page 3389 Manifold Tuning Valve Relay (RT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Diagrams Manifold Tuning Valve Solenoid (RT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Diagrams Manifold Tuning Valve Solenoid (RT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Diagrams > Page 3396 Variable Induction Control Valve: Description and Operation Fig.19 Manifold Turning Valve The valve connects both passages of the intake manifold plenum (Fig. 19). It is an electric motor. The PCM controls the MTV solenoid. The manifold tuning valve optimizes acoustical tuning of the intake system during wide open throttle operation throughout the RPM range. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Diagrams > Page 3397 Variable Induction Control Valve: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Tie the upper radiator hose back to gain access to the Manifold Tuning Valve (MTV). 3. Remove the 3 bolts from the rear power steering bracket. Fig.20 Power Steering Bracket 4 Remove the bracket (Fig. 20). Fig.21 Manifold Tuning Valve (MTV) 5. Remove the 2 bolts from the MTV (Fig. 21). NOTE: When removing the MTV do not loose the spring that is between the valve and intake manifold. 6. Remove the MTV. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Diagrams > Page 3398 Fig.22 Electrical Connector 7. Disconnect the electrical from the MTV and bracket (Fig. 32). INSTALLATION 1. Connect the electrical connector to the MTV and bracket (Fig. 33). NOTE: When removing the MTV do not loose the spring that is between the valve and intake manifold. 2. Install the MTV. Align the slot in the valve with the tab on the intake manifold. Do not forget to install the spring. 3. Install the 2 bolts to the MTV (Fig. 32). 4. Install the bracket (Fig. 31). 5. Install the 3 bolts for the rear power steering bracket. 6. Untie the upper radiator hose. 7. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 3403 The electronic ignition coil pack attaches directly to the valve cover. The 2.0 Liter (122 cu. inch) in-line four cylinder engine is a single over head camshaft with hydraulic lifters and four valves per cylinder design (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3411 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 3416 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3417 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3418 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3419 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3420 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3421 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE ................................................................................................................................................. ........................................................ RESISTANCE # 1, # 4 ................................................................................................................................................. ..................................................... 2970 - 8910 ohms # 2, # 3 ................................................................................................................................................. ..................................................... 2360 - 7070 ohms Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3425 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature silicone materials. All spark plug cable leads are properly identified with cylinder numbers. The inside of most the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3426 Ignition Cable: Service and Repair REMOVAL 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. Remove spark plug cable from coil first. 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. INSTALLATION 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. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Ignition Coil Coil Polarity - Weastec Coil Coil Polarity - Diamond Coil Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3431 Ignition Coil: Mechanical Specifications Ignition Coil Mounting Bolts 11 Nm 8.1 Ft. Lbs. 95 In. Lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3432 Ignition Coil: Locations Fig.11 Ignition Coil Pack The coil pack consists of 2 coils molded together. The coil pack is mounted on the valve cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3433 Ignition Coil Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3434 Ignition Coil: Service Precautions WARNING: THE DIRECT IGNITION SYSTEM GENERATES APPROXIMATELY 40,000 VOLTS. PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3435 Ignition Coil: Description and Operation Fig.11 Ignition Coil Pack The coil pack consists of 2 coils molded together. The coil pack is mounted on the valve cover. WARNING: THE DIRECT IGNITION SYSTEM GENERATES APPROXIMATELY 40,000 VOLTS. PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM. 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 cylinders 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. 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. Refer to Auto Shutdown (ASD) Relay-PCM Output for relay operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3436 Ignition Coil: Service and Repair REMOVAL Fig.13 Electronic Ignition Coil Pack The electronic ignition coil pack attaches directly to the valve cover. Fig.12 Electronic Ignition Coil Connector 1. Disconnect electrical connector from coil pack. 2. Remove coil pack mounting bolts. 3. Remove coil pack. INSTALLATION The electronic ignition coil pack attaches directly to the valve cover. 1. Install coil pack on valve cover. 2. Transfer spark plug cables to new coil pack. The coil pack towers are numbered with the cylinder identification. Be sure the ignition cables snap onto the towers. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3440 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3445 Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Component Locations > Page 3450 Crankshaft Position Sensor: Connector Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3451 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3452 Crankshaft Position Sensor: Description and Operation Fig.13 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). The PCM sends approximately 5 volts to the Halleffect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterwieght, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3453 Fig.14 Timing Reference Notches (NGC) The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The # 8 crankshaft counterweight has a target ring with 32 teeth and notches, including one long referance tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3454 Crankshaft Position Sensor: Service and Repair REMOVAL - 2.0, 2.4, 2.4L TURBO Fig.1 Crankshaft Position Sensor Location The Crankshaft Position Sensor is in the front of the engine block just under the starter motor. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. On 2.4L SRT-4, remove the lower inner cooler hose from the metal tube. Fig.2 Structural Collar And Bending Strut - (Automatic Transaxle Equipped) 4. Remove the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. 6. Remove the crankshaft position sensor bolt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3455 Fig.3 Crankshaft Position Sensor - 2.4L Turbo 7. Remove the sensor. INSTALLATION - 2.0, 2.4, 2.4L Turbo 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (80 ± 15 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install the Structural Collar, refer to the Engine, Structural Collar Removal and Installation section. 6. On 2.4L SRT-4, install the lower inner cooler hose to metal tube and tighten clamp. 7. Lower vehicle. 8. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair "For information regarding this component please refer to steering column service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Fig. 14 Engine (Left Front) (2.0L) - LHD Fig. 45 Engine (Left Front) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3463 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube > Component Information > Service and Repair Spark Plug Tube: Service and Repair SPARK PLUG TUBE REMOVAL 1. Remove the cylinder head cover. 2. Using locking pliers, remove the tube from the cylinder head. Discard old tube. INSTALLATION 1. Clean area around spark plug with Mopar parts cleaner or equivalent. 2. Apply Mopar Stud and Bearing Mount or equivalent to a new tube approximately 1 mm (0.039 inch) from the end in a 3 mm (0.118 inch) wide area. 3. Install sealer end of tube into the cylinder head. Then carefully install the tube using a hardwood block and mallet until the tube is seated into the bottom of the bore. 4. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation Spark Plug Tube Seal - Valve Cover: Description and Operation DESCRIPTION The spark plug tube seals are located in the cylinder head cover. These seals are pressed into the cylinder head cover to seal the outside perimeter of the spark plug tubes. If these seals show signs of hardness and/or cracking, they should be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation > Page 3471 Spark Plug Tube Seal - Valve Cover: Service and Repair REMOVAL 1. Remove the cylinder head cover. 2. Using an appropriate tool, carefully remove spark plug tube seals. Care should be taken not to damage cylinder head cover sealing surfaces. INSTALLATION 1. Clean all sealing surfaces. NOTE: Position seal with the concave side facing the installation tool. 2. Install seals using Special Tool MB-998306. Only hand pressure on tool is needed to install new seals. 3. Install the cylinder head cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3478 Shift Interlock Solenoid: Diagrams Brake Transmission Shift Interlock Solenoid Brake Transmission Shift Interlock Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3482 Shift Solenoid: Diagrams Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3483 8w-80-61 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3484 Solenoid Application Chart Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams Shift Indicator: Diagrams Trans Range Indicator Illumination (PRNDL)(Autostick) Trans Range Indicator Illumination (PRNDL) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Application and ID Transmission Mode Indicator - A/T: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Console Gear Selector w/ Auto ........................................................................................................... .............................................................. PC 194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3503 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3504 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3505 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3511 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3512 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3513 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 3514 Control Module: Locations Fig.11 TCM Location The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 3515 Control Module: Description and Operation Fig.11 TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). It mounts on a bracket that is fastened to the rail. The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: -Battery (B+) voltage -Ignition "ON" voltage -Transmission Control Relay (Switched B+) -Throttle Position Sensor -Crankshaft Position Sensor (CKP) -Transmission Range Sensor (TRS) -Pressure Switches (L/R, 2/4, OD) -Transmission Temperature Sensor (Integral to TRS) -Input Shaft Speed Sensor -Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) - Torque Reduction Request (to PCM) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 3516 An example of a TCM indirect output is: Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.12 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 12). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 3517 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 3518 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation Control Module: Service and Repair Removal and Installation REMOVAL NOTE: If the Transmission Control Module (TCM) is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE STANDARD PROCEDURE) 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Partially remove right front wheel splash shield. Fig.13 TCM 60-Way Connector 4. Disconnect TCM 60-way connector (Fig. 13). Fig.14 TCM/Bracket Assembly 5. Remove three (3) TCM bracket-to-rail screws and remove TCM/bracket assembly from vehicle (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation > Page 3521 Fig.15 TCM Bracket 6. Remove four (4) bracket-to-TCM screws and remove bracket (Fig. 15). INSTALLATION 1. Install TCM to mounting bracket and torque four (4) screws to 12 Nm (105 in. lbs.) (Fig. 15). 2. Install TCM/bracket assembly to rail (Fig. 14). Install and torque three (3) bracket-to-rail screws to 12 Nm (105 in. lbs.). 3. Install TCM 60-way connector and torque to 4 Nm (35 in. lbs.) (Fig. 13). 4. Install and secure right front wheel splash shield. 5. Lower vehicle. 6. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation > Page 3522 Control Module: Service and Repair Pinion Factor Setting STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRB III scan tool. 1. Plug the DRB III scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRB III scan tool screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation > Page 3523 Control Module: Service and Repair Quick Learn Procedure STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB III scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° 1. Plug the DRB III scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRB III to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3527 Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3528 Transmission Control System Relay: Diagrams Automatic Shut Down Relay Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3529 Transmission Control System Relay: Description and Operation 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 303) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications Solenoid/Pressure Switch Assembly-to-Case Bolt ................................................................................................................................ 12 Nm (110 in. lbs.) Solenoid/Pressure Switch Assembly Connector Screw ............................................................................................................................. 4 Nm (35 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3538 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3539 Fluid Pressure Sensor/Switch: Description and Operation 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 289) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3540 The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the chart shown. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate DTC will set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3541 Pressure Switch States Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3542 Fluid Pressure Sensor/Switch: Service and Repair 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 290). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 291). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3543 7. Remove solenoid/pressure switch assembly and gasket (Fig. 292). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 292). 2. Install and torque three (3) bolts (Fig. 291) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 290) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner/throttle body assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Interlock Mechanism Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3547 Shift Interlock Switch: Service and Repair REMOVAL Fig. 39 1. Remove the steering column lower cover (Fig. 39). Fig. 40 2. Remove the steering column upper and lower shrouds (Fig. 40). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3548 Fig. 41 3. Turn the ignition key to the "OFF" or "ON/ RUN" position (Fig. 41). Fig. 42 4. Grasp the interlock cable and connector firmly. Remove the interlock cable (Fig. 42). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3549 Fig. 43 5. Remove the two interlock mechanism-to-steering column attaching screws (Fig. 43). Remove the interlock housing. INSTALLATION 1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 Nm (21 inch lbs.). 2. Snap the interlock cable into the housing. 3. Install steering column upper and lower shrouds (Fig. 40). 4. Install steering column lower cover (Fig. 39). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations > Page 3553 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3557 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3558 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3559 Autostick Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 3565 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 3566 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 3567 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 3568 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 3569 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 3570 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 3571 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 3576 Transmission Speed Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 3577 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3578 Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 293), sealed with an O-ring (Fig. 294), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3581 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 295), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3582 Transmission Speed Sensor: Description and Operation Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 298), sealed with an O-ring (Fig. 299), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3583 OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 300), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3584 Transmission Speed Sensor: Description and Operation Vehicle Speed Signal 41TE - Automatic Transmission VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 296). 5. Inspect speed sensor O-ring (Fig. 297) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Install air cleaner/throttle body assembly. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3587 Transmission Speed Sensor: Service and Repair Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 301). 5. Inspect speed sensor O-ring (Fig. 302) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 302). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor ......................................................................................................................... ..................................................... 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 3592 Transmission Speed Sensor: Description and Operation T350 - Manual Transmission DESCRIPTION - VEHICLE SPEED SENSOR 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 3593 Transmission Speed Sensor: Service and Repair T350 - Manual Transmission VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector (Fig. 151). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt (Fig. 151). 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. Install pinion gear to speed sensor (Fig. 151). 2. Using a NEW O-ring, install the speed sensor to the transaxle (Fig. 151). 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector (Fig. 151). 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard Start/Idle Fluctuation/RPM Sag NUMBER: 18-024-05 GROUP: Vehicle Performance DATE: May 17, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: Driveability Improvements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) Neon 2003 (PT) PT Cruiser 2003 (RS) Town & Country/Caravan/Voyager 2003 (RG) Chrysler Voyager This bulletin applies to: ^ PL vehicles equipped with a 2.0L engine (sales code ECB or ECH). ^ PT vehicles equipped with a 2.0L or 2.4L engine (sales code ECC or EDZ). ^ RS vehicles equipped with a 2.4L engine (sales code EDZ). ^ RG vehicles equipped with a 2.4L engine (sales code EDZ). SYMPTOM/CONDITION: All Vehicles The vehicle operator may experience idle fluctuation. PL Vehicles with a 2.0L Engine (sales codes ECH) or a 2.0L engine and manual transmission (sales code ECB and DD5 or DDR) The vehicle operator may experience one or more of the following: ^ Hard start at temperatures between 9° (48.2° F) and 65° C (149° F). ^ RPM bump while driving when the A/C is turned on. ^ RPM sag on throttle tip-in or tip-out. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate diagnostic procedures on TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the customer describes the Symptom/Condition is present, perform the Repair Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag > Page 3602 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag > Page 3603 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag > Page 3604 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's PROM - Programmable Read Only Memory: Customer Interest A/T - Delayed Gear Engagement/Possible DTC's NUMBER: 21-004-05 GROUP: Transmission DATE: January 22, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-007-04, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES, ADDITIONAL MODEL YEARS. SUBJECT: Transmission Delayed Engagement OVERVIEW: This bulletin involves replacing the front pump assembly in the transmission and checking the Transmission Control Module (TCM) for the latest software revision level. MODELS: 2004 (CS) Pacifica **2002** - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 (KJ) Liberty 2003 (KJ) Cherokee (International Markets) **2002** 2004 (LH) 300M/Concorde/Intrepid **2002**2003 (PL) Neon **2002** 2003 (PT) PT Cruiser **2002** 2003 (RG) Chrysler Voyager (International Markets) **2002** 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's > Page 3609 NOTE: Refer to the table for specific applications. SYMPTOM/CONDITION: Vehicle operator may experience a delayed or temporary loss of transmission engagement after initial start up. The condition follows an extended soak (several hours) and may be accompanied by a harsh 4-3 downshift. Technician may find Diagnostic Trouble Code (DTC) P1791/P0944 - Loss of Prime. DIAGNOSIS: Using a Scan Tool (DRBII I®) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes the Symptom/Condition or the technician finds DTC P1791 or P0944, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's > Page 3610 1. Check the transmission fluid level. If fluid level is full proceed to Step # 2. If fluid level is low, diagnose and repair fluid leak. Proceed to Step # 3. 2. Replace the transmission oil pump. Refer to the service information available in TechCONNECT Group-21, Transmission. 3. Verify the controller has the latest software revision level. 4. If the controller is at the latest revision level, no further action is necessary. If a flash update is available reprogram the controller as instructed in Service Bulletin 21-006-03 Rev. A. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Long Crank/No Start/MIL ON/DTC's NUMBER: 18-026-03 REV A GROUP: Vehicle Performance DATE: September 12, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-026-03, DATED JUNE 27, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS, ADDITIONAL SYMPTOMS/CONDITIONS, ADDITIONAL TOOLS, UPDATED REPAIR PROCEDURE AND A REVISED NOTE. SUBJECT: Flash: Long Crank No Start/MIL Illumination OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) Neon 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager **2004 (CS) Pacifica** NOTE: **This bulletin applies to RS and RG vehicles equipped with a 2.4L engine (sales code EDZ) and all CS, PL and PT vehicles built before date indicated below.** SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3615 Engine no start (engine will start immediately after cycling the ignition key), MIL illumination with any or all of the false Diagnostic Trouble Codes (DTC's). NOTE: Additional false DTC's may be set. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or the technician experiences the Symptom/Condition, perform the Repair Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3616 PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed.** REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R), must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b."1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part #" on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 2. Page back to the "Main Menu" 3. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3617 4. If the vehicle is not equipped with SKIM then proceed to step 5. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 5. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the Daimlerchrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 5. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 6. If the old "PCM part #" is known, proceed to step 12. If the old "PCM part #" is not known, proceed to next step. 7. On DealerCONNECT select the "Service" tab. 8. Select "Vehicle Information Plus". 9. Manually enter the VIN and mileage and select "Enter". 10. Select the "Vehicle Option" tab. 11. Under the "Vehicle Option" window, identify and record: a. Engine. b. Emissions (Federal or California) c. Transmission (Automatic, 5-speed manual, etc.). 12. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 13. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria" area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. 14. Determine the proper calibration: a. If the old "PCM part #" is known, enter the part number of the old controller in the "Parts Criteria" pin window. Proceed to step 15. b. If the old "PCM part #" is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 11. 15. Select the correct calibration. 16. Select the "Download/Update" button. 17. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 18. Enter the VIN in the PCM. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3618 g. If the vehicle is not equipped with SKIM proceed to step 18h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 19. h. Enter the VIN as requested by the DRBIII(R). 19. Update the PCM mileage. Using the DRBIII(R)select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" g. "NO" h. Enter the current odometer mileage and then press "Enter". I. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 20. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 22. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 23. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 21. 21. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 22. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3619 g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. I. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 23. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts PROM - Programmable Read Only Memory: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3624 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3625 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3626 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-03 > Apr > 03 > Engine Controls - Erroneous MIL/DTC's PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Erroneous MIL/DTC's NUMBER: 18-018-03 GROUP: Vehicle Performance DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS CD2132 OR HIGHER, AVAILABLE MAY 12, 2003. THE DRBIII(R) MUST BE OPERATING AT LEVEL 55.7. ISIS MUST BE AT CD2132 (AVAILABLE JUNE 4, 2003) OR HIGHER. SUBJECT: Flash: MIL Illumination, Erroneous Diagnostic Trouble Codes (DTCs) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) Neon/SX 2.0 2003 (PL) SRT-4 2003 (PT) PT Cruiser NOTE: THIS BULLETIN APPLIES TO PL VEHICLES EQUIPPED WITH A 2.0L ENGINE (SALES CODES ECB OR ECH) OR A 2.4L ENGINE (SALES CODE EDV) BUILT ON OR BEFORE MARCH 31, 2003 (MDH 0331XX) AND PT VEHICLES EQUIPPED WITH A 2.0L ENGINE (SALES CODE ECC) OR A 2.41 ENGINE (SALES CODE EDZ OR EDV) BUILT ON OR BEFORE APRIL 28, 2003 (MDH 0428XX). SYMPTOM/CONDITION: Vehicle operator may experience MIL illumination. Technicians may find the following DTC(s): P0071 - Ambient Temperature Sensor Performance. P0111 - Intake Air Temperature Sensor Stuck. P0116 - Engine Coolant Temperature Performance. P0129 - Barometric Pressure Out of Range - Low (Turbo only). P1115 - General Temperature Sensor Performance. DIAGNOSIS: Using a Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or the technician experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-03 > Apr > 03 > Engine Controls - Erroneous MIL/DTC's > Page 3631 EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A CONTROLLER IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a battery charger and set as close to 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MEL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM as necessary and cover the label(s) with the clear plastic overlay. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-03 > Apr > 03 > Engine Controls - Erroneous MIL/DTC's > Page 3632 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-03 > Feb > 03 > Engine Controls - MIL ON/False DTC P0137 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/False DTC P0137 Set NUMBER: 18-003-03 GROUP: Vehicle Performance DATE: Feb. 21, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2127 OR HIGHER, AVAILABLE MARCH 3, 2003. SUBJECT: Flash: Erroneous Diagnostic Trouble Code (DTC) P0137 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) NEON/SX 2.0 NOTE: THE BULLETIN APPLIES TO VEHICLES BUILT BEFORE JANUARY 2, 2003 (MDH 0102XX). SYMPTOM/CONDITION: MIL illumination, DTC P0137, "02 SENSOR VOLTAGE LOW". DIAGNOSIS: Using a Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is present, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A PCM/TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a battery charger and set as close to 14 volts charge as possible. 2. Flash the PCM using the TechConnect (MDS2 (Mopar Diagnostic System) and DRBIII(R). NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-03 > Feb > 03 > Engine Controls - MIL ON/False DTC P0137 Set > Page 3637 DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-03 > Feb > 03 > Engine Controls - MIL ON/False DTC P0137 Set > Page 3638 FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) 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 3644 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 (L4-2.0L VIN F HO (2003)) 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 3645 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 (L4-2.0L VIN F HO (2003)) 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 3646 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 (L4-2.0L VIN F HO (2003)) 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 3647 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 (L4-2.0L VIN F HO (2003)) 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 3648 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 (L4-2.0L VIN F HO (2003)) 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 3649 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 (L4-2.0L VIN F HO (2003)) 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 3650 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3651 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3652 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 3653 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 3654 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 3655 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 (L4-2.0L VIN F HO (2003)) 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 3656 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 (L4-2.0L VIN F HO (2003)) 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 3657 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3658 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3659 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 (L4-2.0L VIN F HO (2003)) 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 3660 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3661 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 (L4-2.0L VIN F HO (2003)) 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 3662 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 (L4-2.0L VIN F HO (2003)) 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: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard Start/Idle Fluctuation/RPM Sag NUMBER: 18-024-05 GROUP: Vehicle Performance DATE: May 17, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: Driveability Improvements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) Neon 2003 (PT) PT Cruiser 2003 (RS) Town & Country/Caravan/Voyager 2003 (RG) Chrysler Voyager This bulletin applies to: ^ PL vehicles equipped with a 2.0L engine (sales code ECB or ECH). ^ PT vehicles equipped with a 2.0L or 2.4L engine (sales code ECC or EDZ). ^ RS vehicles equipped with a 2.4L engine (sales code EDZ). ^ RG vehicles equipped with a 2.4L engine (sales code EDZ). SYMPTOM/CONDITION: All Vehicles The vehicle operator may experience idle fluctuation. PL Vehicles with a 2.0L Engine (sales codes ECH) or a 2.0L engine and manual transmission (sales code ECB and DD5 or DDR) The vehicle operator may experience one or more of the following: ^ Hard start at temperatures between 9° (48.2° F) and 65° C (149° F). ^ RPM bump while driving when the A/C is turned on. ^ RPM sag on throttle tip-in or tip-out. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate diagnostic procedures on TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the customer describes the Symptom/Condition is present, perform the Repair Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag > Page 3667 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag > Page 3668 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-024-05 > May > 05 > Engine Controls - Hard Start/Idle Fluctuation/RPM Sag > Page 3669 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Delayed Gear Engagement/Possible DTC's NUMBER: 21-004-05 GROUP: Transmission DATE: January 22, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-007-04, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES, ADDITIONAL MODEL YEARS. SUBJECT: Transmission Delayed Engagement OVERVIEW: This bulletin involves replacing the front pump assembly in the transmission and checking the Transmission Control Module (TCM) for the latest software revision level. MODELS: 2004 (CS) Pacifica **2002** - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 (KJ) Liberty 2003 (KJ) Cherokee (International Markets) **2002** 2004 (LH) 300M/Concorde/Intrepid **2002**2003 (PL) Neon **2002** 2003 (PT) PT Cruiser **2002** 2003 (RG) Chrysler Voyager (International Markets) **2002** 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's > Page 3674 NOTE: Refer to the table for specific applications. SYMPTOM/CONDITION: Vehicle operator may experience a delayed or temporary loss of transmission engagement after initial start up. The condition follows an extended soak (several hours) and may be accompanied by a harsh 4-3 downshift. Technician may find Diagnostic Trouble Code (DTC) P1791/P0944 - Loss of Prime. DIAGNOSIS: Using a Scan Tool (DRBII I®) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes the Symptom/Condition or the technician finds DTC P1791 or P0944, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's > Page 3675 1. Check the transmission fluid level. If fluid level is full proceed to Step # 2. If fluid level is low, diagnose and repair fluid leak. Proceed to Step # 3. 2. Replace the transmission oil pump. Refer to the service information available in TechCONNECT Group-21, Transmission. 3. Verify the controller has the latest software revision level. 4. If the controller is at the latest revision level, no further action is necessary. If a flash update is available reprogram the controller as instructed in Service Bulletin 21-006-03 Rev. A. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Long Crank/No Start/MIL ON/DTC's NUMBER: 18-026-03 REV A GROUP: Vehicle Performance DATE: September 12, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-026-03, DATED JUNE 27, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS, ADDITIONAL SYMPTOMS/CONDITIONS, ADDITIONAL TOOLS, UPDATED REPAIR PROCEDURE AND A REVISED NOTE. SUBJECT: Flash: Long Crank No Start/MIL Illumination OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) Neon 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager **2004 (CS) Pacifica** NOTE: **This bulletin applies to RS and RG vehicles equipped with a 2.4L engine (sales code EDZ) and all CS, PL and PT vehicles built before date indicated below.** SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3680 Engine no start (engine will start immediately after cycling the ignition key), MIL illumination with any or all of the false Diagnostic Trouble Codes (DTC's). NOTE: Additional false DTC's may be set. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or the technician experiences the Symptom/Condition, perform the Repair Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3681 PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed.** REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R), must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b."1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part #" on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 2. Page back to the "Main Menu" 3. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3682 4. If the vehicle is not equipped with SKIM then proceed to step 5. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 5. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the Daimlerchrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 5. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 6. If the old "PCM part #" is known, proceed to step 12. If the old "PCM part #" is not known, proceed to next step. 7. On DealerCONNECT select the "Service" tab. 8. Select "Vehicle Information Plus". 9. Manually enter the VIN and mileage and select "Enter". 10. Select the "Vehicle Option" tab. 11. Under the "Vehicle Option" window, identify and record: a. Engine. b. Emissions (Federal or California) c. Transmission (Automatic, 5-speed manual, etc.). 12. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 13. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria" area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. 14. Determine the proper calibration: a. If the old "PCM part #" is known, enter the part number of the old controller in the "Parts Criteria" pin window. Proceed to step 15. b. If the old "PCM part #" is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 11. 15. Select the correct calibration. 16. Select the "Download/Update" button. 17. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 18. Enter the VIN in the PCM. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3683 g. If the vehicle is not equipped with SKIM proceed to step 18h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 19. h. Enter the VIN as requested by the DRBIII(R). 19. Update the PCM mileage. Using the DRBIII(R)select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" g. "NO" h. Enter the current odometer mileage and then press "Enter". I. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 20. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 22. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 23. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 21. 21. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 22. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-026-03A > Sep > 03 > Engine Controls - Long Crank/No Start/MIL ON/DTC's > Page 3684 g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. I. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 23. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3689 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3690 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3691 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-018-03 > Apr > 03 > Engine Controls - Erroneous MIL/DTC's PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Erroneous MIL/DTC's NUMBER: 18-018-03 GROUP: Vehicle Performance DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS CD2132 OR HIGHER, AVAILABLE MAY 12, 2003. THE DRBIII(R) MUST BE OPERATING AT LEVEL 55.7. ISIS MUST BE AT CD2132 (AVAILABLE JUNE 4, 2003) OR HIGHER. SUBJECT: Flash: MIL Illumination, Erroneous Diagnostic Trouble Codes (DTCs) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) Neon/SX 2.0 2003 (PL) SRT-4 2003 (PT) PT Cruiser NOTE: THIS BULLETIN APPLIES TO PL VEHICLES EQUIPPED WITH A 2.0L ENGINE (SALES CODES ECB OR ECH) OR A 2.4L ENGINE (SALES CODE EDV) BUILT ON OR BEFORE MARCH 31, 2003 (MDH 0331XX) AND PT VEHICLES EQUIPPED WITH A 2.0L ENGINE (SALES CODE ECC) OR A 2.41 ENGINE (SALES CODE EDZ OR EDV) BUILT ON OR BEFORE APRIL 28, 2003 (MDH 0428XX). SYMPTOM/CONDITION: Vehicle operator may experience MIL illumination. Technicians may find the following DTC(s): P0071 - Ambient Temperature Sensor Performance. P0111 - Intake Air Temperature Sensor Stuck. P0116 - Engine Coolant Temperature Performance. P0129 - Barometric Pressure Out of Range - Low (Turbo only). P1115 - General Temperature Sensor Performance. DIAGNOSIS: Using a Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or the technician experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-018-03 > Apr > 03 > Engine Controls - Erroneous MIL/DTC's > Page 3696 EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A CONTROLLER IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a battery charger and set as close to 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MEL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM as necessary and cover the label(s) with the clear plastic overlay. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-018-03 > Apr > 03 > Engine Controls - Erroneous MIL/DTC's > Page 3697 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-003-03 > Feb > 03 > Engine Controls - MIL ON/False DTC P0137 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/False DTC P0137 Set NUMBER: 18-003-03 GROUP: Vehicle Performance DATE: Feb. 21, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2127 OR HIGHER, AVAILABLE MARCH 3, 2003. SUBJECT: Flash: Erroneous Diagnostic Trouble Code (DTC) P0137 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2003 (PL) NEON/SX 2.0 NOTE: THE BULLETIN APPLIES TO VEHICLES BUILT BEFORE JANUARY 2, 2003 (MDH 0102XX). SYMPTOM/CONDITION: MIL illumination, DTC P0137, "02 SENSOR VOLTAGE LOW". DIAGNOSIS: Using a Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is present, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A PCM/TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a battery charger and set as close to 14 volts charge as possible. 2. Flash the PCM using the TechConnect (MDS2 (Mopar Diagnostic System) and DRBIII(R). NOTE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-003-03 > Feb > 03 > Engine Controls - MIL ON/False DTC P0137 Set > Page 3702 DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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: > 18-003-03 > Feb > 03 > Engine Controls - MIL ON/False DTC P0137 Set > Page 3703 FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) 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 3709 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 (L4-2.0L VIN F HO (2003)) 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 3710 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 (L4-2.0L VIN F HO (2003)) 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 3711 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 (L4-2.0L VIN F HO (2003)) 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 3712 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 (L4-2.0L VIN F HO (2003)) 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 3713 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 (L4-2.0L VIN F HO (2003)) 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 3714 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 (L4-2.0L VIN F HO (2003)) 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 3715 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3716 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3717 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 3718 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 3719 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 3720 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 (L4-2.0L VIN F HO (2003)) 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 3721 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 (L4-2.0L VIN F HO (2003)) 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 3722 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3723 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3724 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 (L4-2.0L VIN F HO (2003)) 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 3725 ^ 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 (L4-2.0L VIN F HO (2003)) 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 3726 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 (L4-2.0L VIN F HO (2003)) 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 3727 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3734 Shift Interlock Solenoid: Diagrams Brake Transmission Shift Interlock Solenoid Brake Transmission Shift Interlock Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3738 Shift Solenoid: Diagrams Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3739 8w-80-61 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3740 Solenoid Application Chart Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3746 Shift Interlock Solenoid: Diagrams Brake Transmission Shift Interlock Solenoid Brake Transmission Shift Interlock Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3750 Shift Solenoid: Diagrams Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3751 8w-80-61 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3752 Solenoid Application Chart Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation Accumulator: Description and Operation 41TE - Automatic Transaxle ACCUMULATOR - DESCRIPTION The 41te underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumulator. An accumulator typically consists of a piston, seals, return spring(s), and a cover or plug. The overdrive and underdrive accumulators are located within the transaxle case, and are retained by the valve body (Fig. 157). The low reverse accumulator (Fig. 158) is also located within the transaxle case, but the assembly is retained by a cover and a snap-ring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Page 3756 The 2/4 accumulator is located in the valve body. It is retained by a cover and retaining screws (Fig. 159). OPERATION The function of an accumulator is to cushion the application of a frictional clutch element. When pressurized fluid is applied to a clutch circuit, the application force is dampened by fluid collecting in the respective accumulator chamber against the piston and spring(s). The intended result is a smooth, firm clutch application. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications CLUTCH CLEARANCES Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Driving Clutches Clutch: Description and Operation Driving Clutches 41TE - Automatic Transaxle DRIVING CLUTCHES - DESCRIPTION Three hydraulically applied input clutches are used to drive planetary components. The underdrive, overdrive, and reverse clutches are considered input clutches and are contained within the input clutch assembly (Fig. 160). The input clutch assembly also contains: - Input shaft - Input hub - Clutch retainer - Underdrive piston - Overdrive/reverse piston - Overdrive hub - Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain. NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first, second, and third (direct) gears by pressurized fluid against the underdrive piston. When the underdrive clutch is applied, the underdrive hub drives the rear sun gear. OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third (direct) and overdrive gears by pressurized fluid against the overdrive/reverse piston. When the overdrive clutch is applied, the overdrive hub drives the front planet carrier. REVERSE CLUTCH Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Driving Clutches > Page 3765 The reverse clutch is hydraulically applied in reverse gear only by pressurized fluid against the overdrive/reverse piston. When the reverse clutch is applied, the front sun gear assembly is driven. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Driving Clutches > Page 3766 Clutch: Description and Operation Holding Clutches 41TE - Automatic Transaxle HOLDING CLUTCHES - DESCRIPTION Two hydraulically applied multi-disc clutches are used to hold planetary geartrain components stationary while the input clutches drive others. The 2/4 and Low/Reverse clutches are considered holding clutches and are contained at the rear of the transaxle case. (Fig. 196). OPERATION NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. 2/4 CLUTCH The 2/4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2/4 clutch piston. When the 2/4 clutch is applied, the front sun gear assembly is held or grounded to the transaxle case. LOW/REVERSE CLUTCH The Low/Reverse clutch is hydraulically applied in park, reverse, neutral, and first gears by pressurized fluid against the Low/Reverse clutch piston. When the Low/Reverse clutch is applied, the front planet carrier/rear annulus assembly is held or grounded to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly Clutch: Service and Repair Disassembly 41TE - Automatic Transaxle Input Clutch Assembly DISASSEMBLY 1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391). 2. Tap down reverse clutch reaction plate to release pressure from snap ring (Fig. 197). 3. Remove reverse clutch snap ring (Fig. 198). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3769 4. Pry up and remove reverse clutch reaction plate (Fig. 199) (Fig. 200). 5. Remove the reverse clutch pack (two fibers/one steel) (Fig. 201). NOTE: Tag reverse clutch pack for reassembly identification. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3770 6. Remove the OD/Reverse pressure plate snap ring (Fig. 202). 7. Remove OD/Reverse pressure plate (Fig. 203). 8. Remove OD/Reverse pressure plate wave snap ring (Fig. 204). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3771 9. Remove OD shaft/hub and OD clutch pack (Fig. 205) (Fig. 206). NOTE: Tag overdrive clutch pack for reassembly identification. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3772 10. Remove and inspect # 3 & # 4 thrust washers (Fig. 207). 11. Remove the underdrive shaft assembly (Fig. 208). 12. Remove the # 2 needle bearing (Fig. 209). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3773 13. Remove the OD/UD reaction plate tapered snap ring (Fig. 210). NOTE: The OD/UD clutch reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. 14. Remove the OD/UD reaction plate (Fig. 211). 15. Remove the first UD clutch disc (Fig. 212). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3774 16. Remove the UD clutch flat snap ring (Fig. 213). NOTE: Tag underdrive clutch pack for reassembly identification. 17. Remove the UD clutch pack (Fig. 214). CAUTION: Compress return spring just enough to remove or install snap ring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3775 18. Using Tool 5059A and an arbor press, compress UD clutch piston enough to remove snap ring (Fig. 215) (Fig. 216). 19. Remove spring retainer (Fig. 216). 20. Remove UD clutch piston (Fig. 217). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3776 21. Remove input hub tapered snap ring (Fig. 218). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3777 22. Tap on input hub with soft faced hammer and separate input hub from OD/Reverse piston and clutch retainer (Fig. 219) (Fig. 220). 23. Separate clutch retainer from OD/Reverse piston (Fig. 221). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3778 24. Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring (Fig. 222) (Fig. 223). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3779 25. Remove input shaft to input clutch hub snap ring (Fig. 224). 26. Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub (Fig. 225). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3780 Clutch: Service and Repair Assembly 41TE - Automatic Transaxle Input Clutch Assembly ASSEMBLY Use petroleum on all seals to ease assembly of components. 1. Using an arbor press, install input shaft to input shaft hub (Fig. 226). 2. Install input shaft snap ring (Fig. 227). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3781 3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig. 228) (Fig. 229). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3782 4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig. 230). 5. Install the input hub/shaft assy. to the OD/Reverse piston/clutch retainer assy. (Fig. 231). 6. Install input hub tapered snap ring (Fig. 232). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3783 7. Install UD clutch piston (Fig. 233). 8. Install UD piston return spring and Tool 5067 as shown in (Fig. 234). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3784 9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring. (Fig. 235) (Fig. 236) Compress just enough to install snap ring. CAUTION: Compress return spring just enough to install snap ring. 10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig. 237). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3785 11. Install the UD clutch flat snap ring (Fig. 238). 12. Install the last UD clutch disc (Fig. 239). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3786 13. Install the OD/UD clutch reaction plate and snap ring (Fig. 240) (Fig. 241). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around. 14. Seat tapered snap ring to ensure proper installation (Fig. 242). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3787 15. Install input clutch assembly to the Input Clutch Pressure Fixture - Tool 8391 (Fig. 243). 16. Set up dial indicator on the UD clutch pack as shown in (Fig. 244). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3788 17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig. 245). When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010. CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack. 18. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart. 19. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94 1.50 mm (0.037 - 0.059 inch). 20. If necessary, select the proper reaction plate to achieve specifications. 21. Install the OD clutch pack (four frictions/three steels) (Fig. 246). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3789 22. Install OD pressure plate waved snap ring (Fig. 247). 23. Install the OD/Reverse pressure plate with large step down (towards OD clutch pack) (Fig. 248). 24. Install OD pressure plate flat snap ring (Fig. 249). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3790 25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse pressure plate as shown in (Fig. 250). 26. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart. 27. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07 3.25 mm (0.042 - 0.128 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance. 28. Install reverse clutch pack (two frictions/one steel) (Fig. 251). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3791 29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 252). 30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring (Fig. 253). 31. Pry up reverse reaction plate to seat against snap ring (Fig. 254). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3792 32. Set up a dial indicator on the reverse clutch pack as shown in (Fig. 255). 33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig. 256). When releasing pressure, indicator should advance 0.005 - 0.010 as clutch pack relaxes. 34. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3793 35. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89 - 1.37 mm (0.035 - 0.054 inch). Select the proper reverse clutch snap ring to achieve specifications. 36. To complete the assembly, reverse clutch and overdrive clutch must be removed. 37. Install the # 2 needle bearing (Fig. 257). 38. Install the underdrive shaft assembly (Fig. 258). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 3794 39. Install the # 3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig. 259). 40. Install the # 3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig. 260). 41. Install the overdrive shaft assembly (Fig. 261). 42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3803 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3804 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3805 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3811 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3812 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3813 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3814 Control Module: Locations Fig.11 TCM Location The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3815 Control Module: Description and Operation Fig.11 TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). It mounts on a bracket that is fastened to the rail. The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: -Battery (B+) voltage -Ignition "ON" voltage -Transmission Control Relay (Switched B+) -Throttle Position Sensor -Crankshaft Position Sensor (CKP) -Transmission Range Sensor (TRS) -Pressure Switches (L/R, 2/4, OD) -Transmission Temperature Sensor (Integral to TRS) -Input Shaft Speed Sensor -Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) - Torque Reduction Request (to PCM) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3816 An example of a TCM indirect output is: Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.12 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 12). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3817 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3818 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Removal and Installation Control Module: Service and Repair Removal and Installation REMOVAL NOTE: If the Transmission Control Module (TCM) is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE STANDARD PROCEDURE) 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Partially remove right front wheel splash shield. Fig.13 TCM 60-Way Connector 4. Disconnect TCM 60-way connector (Fig. 13). Fig.14 TCM/Bracket Assembly 5. Remove three (3) TCM bracket-to-rail screws and remove TCM/bracket assembly from vehicle (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 3821 Fig.15 TCM Bracket 6. Remove four (4) bracket-to-TCM screws and remove bracket (Fig. 15). INSTALLATION 1. Install TCM to mounting bracket and torque four (4) screws to 12 Nm (105 in. lbs.) (Fig. 15). 2. Install TCM/bracket assembly to rail (Fig. 14). Install and torque three (3) bracket-to-rail screws to 12 Nm (105 in. lbs.). 3. Install TCM 60-way connector and torque to 4 Nm (35 in. lbs.) (Fig. 13). 4. Install and secure right front wheel splash shield. 5. Lower vehicle. 6. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 3822 Control Module: Service and Repair Pinion Factor Setting STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRB III scan tool. 1. Plug the DRB III scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRB III scan tool screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 3823 Control Module: Service and Repair Quick Learn Procedure STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB III scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° 1. Plug the DRB III scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRB III to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3829 Differential Fluid - A/T: Fluid Type Specifications 41TE AUTOMATIC TRANSAXLE Recommended Fluid Type ........................................................................................................................................................ Mopar ATF +4, Type 9602 Recommended Sealer ......................................................................................................................... .......................................... Mopar RTV (MS-GF41) NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Page 3830 Differential Fluid - A/T: Testing and Inspection 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Page 3831 Differential Fluid - A/T: Service and Repair 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3836 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3837 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3838 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3839 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3840 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transaxle Estimated Service Fill .......................................................................................................................... ............................................................. 4.0 Qt (3.8L) Overhaul Fill Capacity w/Torque Converter Empty .......................................................................................................................................... 8.6 Qt (8.1L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3843 Fluid - A/T: Fluid Type Specifications 41TE AUTOMATIC TRANSAXLE Automatic Transmission Fluid .................................................................................................................................................... Mopar ATF +4, Type 9602 NOTE: The 41TE automatic and T350 manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3844 Fluid - A/T: Service Precautions CAUTION: Using a transmission fluid other than ATF +4 may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than ATF +4 will result in more frequent fluid and filter changes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing Fluid - A/T: Testing and Inspection Diagnosis and Testing Effects of Incorrect Fluid Level DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation and varnish build up which interferes with valve and clutch operation. Foaming also causes fluid expansion, which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Fluid Contamination DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: * adding incorrect fluid * failure to clean dipstick and fill tube when checking level * engine coolant entering the fluid * internal failure that generates debris * overheat that generates sludge (fluid breakdown) * failure to reverse flush cooler and lines after repair * failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Causes of Burnt Fluid DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 3847 Fluid - A/T: Testing and Inspection Fluid Level and Condition Check 41TE - Automatic Transaxle FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF +4 (Automatic Transmission Fluid Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82 °C (180 °F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 180). The fluid level should be within the COLD region of the dipstick at 27 °C (80 °F) fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 3848 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 181). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF +4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF +4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check Procedure for Checking Fluid Level Check the fluid level while the transmission is at normal operating temperature. this occurs after at least 15 miles (25 km) of driving. At normal operating temperature, which is approximately 180 °F (82 °C), the fluid cannot be held comfortably between the fingers. To check the fluid level properly, the following procedure must be used: 1. The vehicle must be on level ground. 2. The engine should be running at curb idle speed for a minimum of 60 seconds. 3. Fully apply parking brake. 4. Place the gear selector momentarily in each gear position ending with the lever in P (PARK). 5. Remove the dipstick, wipe it clean and reinsert it until seated. 6. Remove the dipstick again and note the fluid level on both sides. The fluid level should be in the crosshatch area at normal operating temperatures. If the fluid is low, add as required into the dipstick tube. DO NOT OVERFILL. Note: If it is necessary to check the transmission below the operating temperature, the fluid level should be between the two cold (lower) holes on the dipstick with the fluid approximately 80 °F (27 °C) (room temperature). If the fluid level is correctly established at room temperature, it should be between the HOT (upper) reference holes when the transmission reaches 180 °F (82 °C). Remember, it is best to check the level at the normal operating temperature. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3851 Fluid - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 182). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 in. lbs.). 5. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3852 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 182). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 in. lbs.). 5. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 3856 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 183). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Description and Operation Fluid Line/Hose: Description and Operation DESCRIPTION The transmission oil cooling circuit uses special aggressive fittings for the transmission oil cooler hoses. Whenever a transmission oil cooler hose is removed from a transmission fitting (at transmission), it must be cut off flush with the fitting, and a service splice kit must be used upon reassembly Refer to instructions provided with splice kit. Whenever a transmission oil cooler hose is removed from a transmission oil cooler fitting (at radiator), it must be replaced with a new hose. Removing the hose from the aggressive fitting will scrape material from inside the hose making the hose larger. Failure to replace the hose or install a service splice kit will result in transmission oil leaks. When hose clamp replacement is necessary, replace with constant tension spring type hose clamps. Always use proper hose clamp pliers on clamps. Use of improper hose clamp pliers may bend hose clamps out-of-round resulting in transmission oil leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Cooler Lines Removal and Installation Fluid Line/Hose: Service and Repair Transmission Cooler Lines Removal and Installation 41TE - Automatic Transmission REMOVAL 1. While holding tension on hose clamps with pliers, move clamps off the fitting location of hose. 2. Disconnect hoses from cooler (Fig. 2). Disconnect hoses from transmission fittings (Fig. 3). 3. Remove cooler hoses. INSTALLATION NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Cooler Lines Removal and Installation > Page 3862 1. Connect hoses to cooler (Fig. 2) and transmission (Fig. 3) fittings. 2. Position and install hose clamps. 3. Start engine and check transmission fluid level. Adjust level as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Cooler Lines Removal and Installation > Page 3863 Fluid Line/Hose: Service and Repair Flushing Coolers and Tubes 41TE - Automatic Transmission FLUSHING COOLERS AND TUBES The recommended procedure for cooler flushing is to use Tool 6906 Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIT 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. 1. Remove cover plate filler plug on Tool 6906. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Use Mopar Transmission Cooler Flush (MS-552) or equivalent solution conforming to MS-552. 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. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 4. Connect the BLUE pressure line to the OUTLET (From) cooler line. 5. Connect the CLEAR return line to the INLET (To) cooler line 6. Turn pump ON for two to three minutes to flush cooler and lines. 7. Turn pump OFF. 8. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 9. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 10. Place CLEAR suction line into a one quart container of Mopar ATF +4 (Automatic Transmission Fluid-Type 9602). 11. 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. 12. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil Pan-to-Case Bolt ............................................................................................................................ ................................................. 19 Nm (165 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications Solenoid/Pressure Switch Assembly-to-Case Bolt ................................................................................................................................ 12 Nm (110 in. lbs.) Solenoid/Pressure Switch Assembly Connector Screw ............................................................................................................................. 4 Nm (35 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3870 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3871 Fluid Pressure Sensor/Switch: Description and Operation 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 289) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3872 The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the chart shown. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate DTC will set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3873 Pressure Switch States Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3874 Fluid Pressure Sensor/Switch: Service and Repair 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 290). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 291). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3875 7. Remove solenoid/pressure switch assembly and gasket (Fig. 292). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 292). 2. Install and torque three (3) bolts (Fig. 291) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 290) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner/throttle body assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-004-05 > Jan > 05 > A/T Delayed Gear Engagement/Possible DTC's Fluid Pump: Customer Interest A/T - Delayed Gear Engagement/Possible DTC's NUMBER: 21-004-05 GROUP: Transmission DATE: January 22, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-007-04, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES, ADDITIONAL MODEL YEARS. SUBJECT: Transmission Delayed Engagement OVERVIEW: This bulletin involves replacing the front pump assembly in the transmission and checking the Transmission Control Module (TCM) for the latest software revision level. MODELS: 2004 (CS) Pacifica **2002** - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 (KJ) Liberty 2003 (KJ) Cherokee (International Markets) **2002** 2004 (LH) 300M/Concorde/Intrepid **2002**2003 (PL) Neon **2002** 2003 (PT) PT Cruiser **2002** 2003 (RG) Chrysler Voyager (International Markets) **2002** 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-004-05 > Jan > 05 > A/T Delayed Gear Engagement/Possible DTC's > Page 3884 NOTE: Refer to the table for specific applications. SYMPTOM/CONDITION: Vehicle operator may experience a delayed or temporary loss of transmission engagement after initial start up. The condition follows an extended soak (several hours) and may be accompanied by a harsh 4-3 downshift. Technician may find Diagnostic Trouble Code (DTC) P1791/P0944 - Loss of Prime. DIAGNOSIS: Using a Scan Tool (DRBII I®) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes the Symptom/Condition or the technician finds DTC P1791 or P0944, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-004-05 > Jan > 05 > A/T Delayed Gear Engagement/Possible DTC's > Page 3885 1. Check the transmission fluid level. If fluid level is full proceed to Step # 2. If fluid level is low, diagnose and repair fluid leak. Proceed to Step # 3. 2. Replace the transmission oil pump. Refer to the service information available in TechCONNECT Group-21, Transmission. 3. Verify the controller has the latest software revision level. 4. If the controller is at the latest revision level, no further action is necessary. If a flash update is available reprogram the controller as instructed in Service Bulletin 21-006-03 Rev. A. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's Fluid Pump: All Technical Service Bulletins A/T - Delayed Gear Engagement/Possible DTC's NUMBER: 21-004-05 GROUP: Transmission DATE: January 22, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-007-04, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES, ADDITIONAL MODEL YEARS. SUBJECT: Transmission Delayed Engagement OVERVIEW: This bulletin involves replacing the front pump assembly in the transmission and checking the Transmission Control Module (TCM) for the latest software revision level. MODELS: 2004 (CS) Pacifica **2002** - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 (KJ) Liberty 2003 (KJ) Cherokee (International Markets) **2002** 2004 (LH) 300M/Concorde/Intrepid **2002**2003 (PL) Neon **2002** 2003 (PT) PT Cruiser **2002** 2003 (RG) Chrysler Voyager (International Markets) **2002** 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's > Page 3891 NOTE: Refer to the table for specific applications. SYMPTOM/CONDITION: Vehicle operator may experience a delayed or temporary loss of transmission engagement after initial start up. The condition follows an extended soak (several hours) and may be accompanied by a harsh 4-3 downshift. Technician may find Diagnostic Trouble Code (DTC) P1791/P0944 - Loss of Prime. DIAGNOSIS: Using a Scan Tool (DRBII I®) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes the Symptom/Condition or the technician finds DTC P1791 or P0944, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-004-05 > Jan > 05 > A/T - Delayed Gear Engagement/Possible DTC's > Page 3892 1. Check the transmission fluid level. If fluid level is full proceed to Step # 2. If fluid level is low, diagnose and repair fluid leak. Proceed to Step # 3. 2. Replace the transmission oil pump. Refer to the service information available in TechCONNECT Group-21, Transmission. 3. Verify the controller has the latest software revision level. 4. If the controller is at the latest revision level, no further action is necessary. If a flash update is available reprogram the controller as instructed in Service Bulletin 21-006-03 Rev. A. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3893 Fluid Pump: Description and Operation 41TE - Automatic Transmission OIL PUMP - DESCRIPTION The oil pump is located in the pump housing inside the bell housing of the transaxle case (Fig. 262). The oil pump consists of an inner and outer gear, a housing, and a cover that also serves as the reaction shaft support. OPERATION As the torque converter rotates, the converter hub rotates the inner and outer gears. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. This suction draws fluid through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces pressurized fluid into the pump outlet and to the valve body. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3894 Fluid Pump: Testing and Inspection 41TE - Automatic Transmission STANDARD PROCEDURE - OIL PUMP VOLUME CHECK Measuring oil pump output volume will determine if sufficient flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that transmission fluid is at the proper level. If adding fluid is necessary, fill to the proper level with Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). The following procedure is to check oil pump output volume: 1. Using hose cutters or a suitable blade, cut the "to cooler" (Fig. 263) line off flush with the cooler inlet fitting and place a collection container under the open line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Start engine and run at curb idle speed, with the shift selector in neutral. 3. If one quart of ATF is collected in 20 seconds or less, flow is within acceptable limits. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF, Refer to DIAGNOSIS AND TESTING. 4. Inspect the cooler hose for damage. Replace if necessary. 5. Re-connect the to cooler line to the transmission using a service splice kit. Refer to instructions included with the kit. 6. Refill the transaxle to proper level with Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly Fluid Pump: Service and Repair Disassembly 41TE - Automatic Transmission DISASSEMBLY When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage. 1. Remove the reaction shaft support bolts. 2. Remove reaction shaft support from pump housing (Fig. 264). 3. Remove the pump gears (Fig. 265) and check for wear and damage on pump housing and gears. 4. Re-install the gears and check clearances. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3897 5. Measure the clearance between the outer gear and the pump pocket (Fig. 266). Clearance should be 0.089 - 0.202 mm (0.0035 - 0.0079 inch). 6. Measure clearance between outer gear and crescent. Clearance should be 0.060 - 0.298 mm (0.0023 - 0.0117 inch). 7. Measure clearance between inner gear and crescent. Clearance should be 0.093 - 0.385 mm (0.0036 - 0.0151 inch). 8. Position an appropriate piece of Plastigage across both pump gears. 9. Align the Plastigage to a flat area on the reaction shaft support housing. 10. Install the reaction shaft to the pump housing. Tighten the bolts to 27 Nm (20 ft. lbs.). 11. Remove bolts and carefully separate the housings. Measure the Plastigage following the instructions supplied. 12. Clearance between outer gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.0008 - 0.0018 inch). Clearance between inner gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.0008 - 0.0018 inch). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3898 Fluid Pump: Service and Repair Assembly 41TE - Automatic Transmission ASSEMBLY 1. Assemble oil pump as shown in (Fig. 267) 2. Install and torque reaction shaft support-to-oil pump housing bolts to 28 Nm (20 ft. lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Diagrams Shift Indicator: Diagrams Trans Range Indicator Illumination (PRNDL)(Autostick) Trans Range Indicator Illumination (PRNDL) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Application and ID Transmission Mode Indicator - A/T: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Console Gear Selector w/ Auto ........................................................................................................... .............................................................. PC 194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation Planetary Gears: Description and Operation 41TE - Automatic Transmission PLANETARY GEARTRAIN - DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case. The planetary geartrain consists of two sun gears, two planetary carriers, two annulus (ring) gears, and one output shaft (Fig. 268). OPERATION The planetary geartrain utilizes two planetary gear sets that connect the transmission input shaft to the output shaft. Input and holding clutches drive or lock different planetary members to change output ratio or direction. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3918 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3919 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3920 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3926 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3927 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 3928 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3929 Control Module: Locations Fig.11 TCM Location The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3930 Control Module: Description and Operation Fig.11 TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). It mounts on a bracket that is fastened to the rail. The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: -Battery (B+) voltage -Ignition "ON" voltage -Transmission Control Relay (Switched B+) -Throttle Position Sensor -Crankshaft Position Sensor (CKP) -Transmission Range Sensor (TRS) -Pressure Switches (L/R, 2/4, OD) -Transmission Temperature Sensor (Integral to TRS) -Input Shaft Speed Sensor -Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) - Torque Reduction Request (to PCM) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3931 An example of a TCM indirect output is: Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.12 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 12). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3932 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3933 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation Control Module: Service and Repair Removal and Installation REMOVAL NOTE: If the Transmission Control Module (TCM) is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE STANDARD PROCEDURE) 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Partially remove right front wheel splash shield. Fig.13 TCM 60-Way Connector 4. Disconnect TCM 60-way connector (Fig. 13). Fig.14 TCM/Bracket Assembly 5. Remove three (3) TCM bracket-to-rail screws and remove TCM/bracket assembly from vehicle (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 3936 Fig.15 TCM Bracket 6. Remove four (4) bracket-to-TCM screws and remove bracket (Fig. 15). INSTALLATION 1. Install TCM to mounting bracket and torque four (4) screws to 12 Nm (105 in. lbs.) (Fig. 15). 2. Install TCM/bracket assembly to rail (Fig. 14). Install and torque three (3) bracket-to-rail screws to 12 Nm (105 in. lbs.). 3. Install TCM 60-way connector and torque to 4 Nm (35 in. lbs.) (Fig. 13). 4. Install and secure right front wheel splash shield. 5. Lower vehicle. 6. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 3937 Control Module: Service and Repair Pinion Factor Setting STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRB III scan tool. 1. Plug the DRB III scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRB III scan tool screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 3938 Control Module: Service and Repair Quick Learn Procedure STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB III scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° 1. Plug the DRB III scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRB III to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3942 Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3943 Transmission Control System Relay: Diagrams Automatic Shut Down Relay Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3944 Transmission Control System Relay: Description and Operation 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 303) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair 41TE - Automatic Transmission SEAL, OIL PUMP REMOVAL 1. Remove transaxle from vehicle. 2. Using Tool C-3981-B, remove oil pump seal (Fig. 269). INSTALLATION 1. Using Tool C-4193, install oil pump seal (Fig. 270). 2. Install transaxle to vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications Solenoid/Pressure Switch Assembly-to-Case Bolt ................................................................................................................................ 12 Nm (110 in. lbs.) Solenoid/Pressure Switch Assembly Connector Screw ............................................................................................................................. 4 Nm (35 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3955 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3956 Fluid Pressure Sensor/Switch: Description and Operation 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 289) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3957 The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the chart shown. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate DTC will set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3958 Pressure Switch States Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3959 Fluid Pressure Sensor/Switch: Service and Repair 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 290). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 291). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 3960 7. Remove solenoid/pressure switch assembly and gasket (Fig. 292). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 292). 2. Install and torque three (3) bolts (Fig. 291) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 290) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner/throttle body assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Interlock Mechanism Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 3964 Shift Interlock Switch: Service and Repair REMOVAL Fig. 39 1. Remove the steering column lower cover (Fig. 39). Fig. 40 2. Remove the steering column upper and lower shrouds (Fig. 40). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 3965 Fig. 41 3. Turn the ignition key to the "OFF" or "ON/ RUN" position (Fig. 41). Fig. 42 4. Grasp the interlock cable and connector firmly. Remove the interlock cable (Fig. 42). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 3966 Fig. 43 5. Remove the two interlock mechanism-to-steering column attaching screws (Fig. 43). Remove the interlock housing. INSTALLATION 1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 Nm (21 inch lbs.). 2. Snap the interlock cable into the housing. 3. Install steering column upper and lower shrouds (Fig. 40). 4. Install steering column lower cover (Fig. 39). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations > Page 3970 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3974 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3975 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3976 Autostick Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3982 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3983 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3984 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3985 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3986 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3987 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3988 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 3993 Transmission Speed Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 3994 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3995 Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 293), sealed with an O-ring (Fig. 294), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3998 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 295), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3999 Transmission Speed Sensor: Description and Operation Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 298), sealed with an O-ring (Fig. 299), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4000 OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 300), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4001 Transmission Speed Sensor: Description and Operation Vehicle Speed Signal 41TE - Automatic Transmission VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 296). 5. Inspect speed sensor O-ring (Fig. 297) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Install air cleaner/throttle body assembly. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4004 Transmission Speed Sensor: Service and Repair Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 301). 5. Inspect speed sensor O-ring (Fig. 302) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 302). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments Shift Interlock Cable: Adjustments 41TE - Automatic Transmission BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM VERIFICATION The chart shown describes the normal operation of the Brake Transmission Shift Interlock (BTSI) system. If the "expected response" differs from the vehicle's response, then system repair and/or adjustment is necessary. ADJUSTMENT 1. Loosen set screw and remove knob from shifter handle (Fig. 286). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 4009 2. Remove the center console assembly as shown in (Fig. 287). 3. Remove shifter bezel (Fig. 288). 4. Adjust interlock cable/system as follows: Pry up on cable adjuster lock to release and allow cable to "self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing. 5. Verify correct system operation. Refer to verification procedure. 6. Install shifter bezel (Fig. 288). 7. Install center console assembly (Fig. 287). 8. Install gearshift knob and tighten set screw to 2 Nm (15 in. lbs.) torque (Fig. 286). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 4010 Shift Interlock Cable: Service and Repair 41TE - Automatic Transmission SHIFT INTERLOCK CABLE - REMOVAL 1. Disconnect the battery negative cable. 2. Loosen set screw and remove knob from shifter handle (Fig. 271). 3. Remove the center console assembly as shown in (Fig. 272). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 4011 4. Remove shifter bezel (Fig. 273). 5. Disconnect the shifter/ignition interlock cable from the shifter lever and bracket as shown in (Fig. 274). Remove the cable core end from the plastic cam of the shifter mechanism and release cable from shifter bracket. 6. Remove the steering column lower cover (Fig. 275). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 4012 7. Remove the steering column upper and lower shrouds (Fig. 276). 8. Disconnect the Brake Transmission Shift Interlock (BTSI) solenoid connector from the interlock cable (Fig. 277). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 4013 9. Rotate the ignition key to the "OFF" or "ON/RUN" position (Fig. 278). 10. Squeeze the interlock cable locking tab. Remove the cable from the interlock housing (Fig. 279). 11. Release cable from retaining clips and remove through opening under steering column. 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 through hole in instrument panel below steering column and around to gear shifter assembly. 2. Turn the ignition key to the "OFF" or "ON/RUN" position (Fig. 278). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 4014 3. Install the interlock cable into the interlock housing at the steering column (Fig. 280). Verify the cable snaps into the housing and is fully seated. 4. Return the ignition key to the "LOCK" position (Fig. 278). 5. Connect the BTSI solenoid connector (Fig. 277). 6. Install cable into retaining clips as shown in (Fig. 277). 7. Install steering column upper and lower shrouds (Fig. 276). 8. Install steering column lower cover (Fig. 275). 9. Verify that shifter is in gated "PARK". 10. 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 as shown in (Fig. 274). 11. Adjust interlock cable/system as follows: If interlock cable is being replaced, it will come with an adjustment pin. Remove the pin from the cable and allow the cable to "self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing. If interlock cable is being re-used, no pin will be provided. Pry up on cable adjuster lock to release and allow cable to "self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing. 12. Connect battery negative cable and verify interlock system operation as shown. 13. Install shifter bezel (Fig. 273). 14. Install center console assembly (Fig. 272). 15. Install gearshift knob and tighten set screw to 2 Nm (15 in. lbs.) torque (Fig. 271). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4018 Shift Interlock Solenoid: Diagrams Brake Transmission Shift Interlock Solenoid Brake Transmission Shift Interlock Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Interlock Mechanism Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 4022 Shift Interlock Switch: Service and Repair REMOVAL Fig. 39 1. Remove the steering column lower cover (Fig. 39). Fig. 40 2. Remove the steering column upper and lower shrouds (Fig. 40). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 4023 Fig. 41 3. Turn the ignition key to the "OFF" or "ON/ RUN" position (Fig. 41). Fig. 42 4. Grasp the interlock cable and connector firmly. Remove the interlock cable (Fig. 42). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 4024 Fig. 43 5. Remove the two interlock mechanism-to-steering column attaching screws (Fig. 43). Remove the interlock housing. INSTALLATION 1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 Nm (21 inch lbs.). 2. Snap the interlock cable into the housing. 3. Install steering column upper and lower shrouds (Fig. 40). 4. Install steering column lower cover (Fig. 39). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4028 Shift Solenoid: Diagrams Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4029 8w-80-61 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4030 Solenoid Application Chart Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments 41TE - Automatic Transmission GEARSHIFT CABLE Normal operation of the Park/Neutral Position Switch provides a quick check to confirm proper linkage adjustment. The engine starter should only operate when the transaxle shift lever is in the PARK (P) or NEUTRAL (N) positions. If the engine starts in any other gear position, or the vehicle rolls when the shifter is in gated PARK (P), a gearshift cable adjustment is necessary. ADJUSTMENT 1. Loosen set screw and remove knob from shifter handle (Fig. 193). 2. Remove the center console assembly as shown in (Fig. 194). 3. Adjust gearshift cable as follows: a. Place gearshift lever in the PARK (P) position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4035 b. Loosen shift cable adjustment screw (Fig. 195). c. Move transaxle manual lever to the PARK. Verify transaxle is in PARK by attempting to roll vehicle in either direction. d. Tighten shift cable adjustment screw to 8 Nm (70 in. lbs.) torque. 4. Verify proper cable adjustment. Engine should start with the shifter lever in PARK (P) and NEUTRAL (N) positions ONLY. 5. Install center console assembly (Fig. 194). 6. Install gearshift knob and tighten set screw to 2 Nm (15 in. lbs.) torque (Fig. 193). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4036 Shift Cable: Service and Repair 41TE - Automatic Transmission GEARSHIFT CABLE - REMOVAL 1. Loosen set screw and remove knob from shifter handle (Fig. 184). 2. Remove the center console assembly as shown in (Fig. 185). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4037 3. Remove shifter bezel (Fig. 186). 4. Disconnect shift cable from shifter assembly as shown in (Fig. 187). 5. Remove three grommet plate to floor pan nuts as shown in (Fig. 187). 6. Disconnect both battery cables, remove battery hold down clamp and bolt, and remove battery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4038 7. Remove air cleaner/throttle body assy. (Fig. 188) as follows: a. Disconnect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body. b. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. c. Remove mounting bolt and nut (Fig. 188) and partially remove air cleaner assembly. d. Disconnect accelerator and speed control (if equipped) cables after the assy. is removed from position. Remove air cleaner assembly from vehicle. 8. Remove battery tray from bracket. 9. Disconnect shifter cable from shift lever and remove from bracket (Fig. 189). 10. Raise vehicle on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4039 11. Remove catalytic converter heat shield (Fig. 190). 12. Remove intermediate pipe heat shield front bolts. 13. Remove remaining grommet plate screw and remove cable assembly from vehicle (Fig. 191). INSTALLATION 1. Install cable assembly through floor pan opening and secure to floor pan with grommet plate and one screw (Fig. 191). Make sure the three grommet plate studs protrude through cable assembly and floor pan and tighten screw to 7 Nm (60 in. lbs.). 2. Route transaxle end of cable assembly into engine compartment and over transaxle assembly. 3. Install and tighten intermediate pipe heat shield front screws. 4. Install catalytic converter heat shield (Fig. 190). 5. Install gear shift cable to bracket and connect to shift lever (Fig. 189). 6. Install and tighten the three grommet plate-to-floor pan nuts. Tighten to 6 Nm (50 in. lbs.) torque. 7. Connect gearshift cable to shifter assembly as shown in (Fig. 187). 8. Install shifter bezel (Fig. 186). 9. Adjust gearshift cable as follows: a. Place gearshift lever in the PARK (P) position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4040 b. Loosen shift cable adjustment screw (Fig. 192). c. Verify transaxle is in the PARK (P) position and the shifter lever is in gated PARK. d. Tighten shift cable adjustment screw to 8 Nm (70 in. lbs.) torque. 10. Install battery tray. 11. Install battery and hold down clamp. 12. Install the air cleaner/throttle body assy. (Fig. 188) as follows: a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assy. b. Install assy. into position, making sure the air cleaner locating slot is engaged to the battery bracket tab, and tighten fasteners to 14 Nm (120 in. lbs.) torque. c. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 Nm (40 in. lbs.) torque. d. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. e. Connect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body. 13. Install center console assembly (Fig. 185). 14. Install gearshift knob and tighten set screw to 2 Nm (15 in. lbs.) torque (Fig. 184). 15. Connect battery cables. 16. Verify that engine starter operates in both PARK (P) and NEUTRAL (N). Starter should not operate in any other gear position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid Position Sensor/Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid Position Sensor/Switch > Component Information > Locations > Page 4044 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Bolt, Torque Converter-to-Driveplate ...................................................................................................................................................... 75 Nm (55 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4051 Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4052 Transmission Control System Relay: Diagrams Automatic Shut Down Relay Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4053 Transmission Control System Relay: Description and Operation 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 303) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation Transmission Cooler: Description and Operation 41TE - Automatic Transmission DESCRIPTION The transmission oil cooler is an oil to coolant type, mounted in the radiator lower tank (Fig. 1). Rubber hoses connect the oil cooler and the automatic transmission. Use only approved transmission oil cooler hoses that are molded to fit the applicable vehicle. The transmission cooler is serviced with the radiator. OPERATION As oil flows through the cooler, heat from the oil is transferred to the coolant. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Flushing Coolers and Tubes Transmission Cooler: Service and Repair Flushing Coolers and Tubes 41TE - Automatic Transmission FLUSHING COOLERS AND TUBES The recommended procedure for cooler flushing is to use Tool 6906 Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIT 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. 1. Remove cover plate filler plug on Tool 6906. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Use Mopar Transmission Cooler Flush (MS-552) or equivalent solution conforming to MS-552. 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. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 4. Connect the BLUE pressure line to the OUTLET (From) cooler line. 5. Connect the CLEAR return line to the INLET (To) cooler line 6. Turn pump ON for two to three minutes to flush cooler and lines. 7. Turn pump OFF. 8. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 9. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 10. Place CLEAR suction line into a one quart container of Mopar ATF +4 (Automatic Transmission Fluid-Type 9602). 11. 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. 12. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Flushing Coolers and Tubes > Page 4059 Transmission Cooler: Service and Repair Transmission Oil Cooler 41TE - Automatic Transmission REMOVAL The transmission cooler is serviced with the radiator assembly. CLEANING If internal cleaning is necessary Refer to FLUSHING COOLERS AND TUBES. INSPECTION Inspect all hoses, tubes, clamps and connections for leaks, cracks, or damage. Replace as necessary. Use only approved transmission oil cooler hoses that are molded to fit the space available. Inspect external coolers for leaks, loose mounts, or damage. Replace as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Application and ID Transmission Mode Indicator - A/T: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Console Gear Selector w/ Auto ........................................................................................................... .............................................................. PC 194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 4066 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 4067 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 4068 Autostick Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 4074 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 4075 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4076 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4077 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4078 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4079 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4080 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4088 Transmission Speed Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4089 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4090 Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 293), sealed with an O-ring (Fig. 294), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4093 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 295), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4094 Transmission Speed Sensor: Description and Operation Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 298), sealed with an O-ring (Fig. 299), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4095 OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 300), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4096 Transmission Speed Sensor: Description and Operation Vehicle Speed Signal 41TE - Automatic Transmission VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 296). 5. Inspect speed sensor O-ring (Fig. 297) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Install air cleaner/throttle body assembly. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4099 Transmission Speed Sensor: Service and Repair Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 301). 5. Inspect speed sensor O-ring (Fig. 302) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 302). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set Valve Body: Customer Interest A/T - MIL ON/DTC P1776 Set NUMBER: 21-008-04 REV. A GROUP: Transmission DATE: October 16, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-008-04, DATED JUNE 1, 2004. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL YEAR AND A UPDATED DISCUSSION. SUBJECT: MIL Illumination - DTC P1776 Solenoid Switch Valve Latched in LR Position MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - 2004 (KJ) Liberty 2003 - 2004 (KJ) Cherokee (International Markets) **2002** - 2004 (LH) 300M/Concorde/Intrepid 2003-2004 (PL) Neon/SX2.0 2003 - 2005 (PT) PT Cruiser 2003 - 2005 (RG) Chrysler Voyager (International Markets) 2003 - 2005 (RS) Town & Country/Voyager/Caravan 2003 - 2004 (TJ) Wrangler NOTE: Refer to the following table for specific applications. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 4108 DISCUSSION: If the vehicle operator describes a MIL illumination and the technician finds DTC P1776 Solenoid Switch Valve Latched in LR Position is set the DRBIII(R) can be used to access the event data screen and look at the "TRS Code" reading. NOTE: The solenoid switch valve is not in the solenoid pack it is in the valve body. TRS Code Reads TR2 If the TRS Code displays TR2 it is an indication that the manual valve was not fully in the OD position at the time the DTC was set. Check the shifter cable adjustment and adjust if necessary. Also check the shift control system for excessive friction and/or routing issues. TRS Code Reads OD If the "TRS Code displays "OD" then a sticky solenoid switch valve is the primary cause. Perform the proper diagnosis for the valve body. Inspect for foreign material in the solenoid switch valve and plugs. **FOR 2002 - 2004 LH MODEL ONLY** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 4109 **If replacing the valve body assembly for DTC P1776 Solenoid Switch Valve Latched in LR Position first inspect the build date on the solenoid pack (Fig. 1) or (Fig. 2). If the build date range falls in between 3001 and 0603 replace the solenoid pack not the valve body** NOTE: The first three characters are the day of the year, the fourth character is the year, ie. 3001 is the 300th day of 2001. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P1776 Set NUMBER: 21-008-04 REV. A GROUP: Transmission DATE: October 16, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-008-04, DATED JUNE 1, 2004. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL YEAR AND A UPDATED DISCUSSION. SUBJECT: MIL Illumination - DTC P1776 Solenoid Switch Valve Latched in LR Position MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - 2004 (KJ) Liberty 2003 - 2004 (KJ) Cherokee (International Markets) **2002** - 2004 (LH) 300M/Concorde/Intrepid 2003-2004 (PL) Neon/SX2.0 2003 - 2005 (PT) PT Cruiser 2003 - 2005 (RG) Chrysler Voyager (International Markets) 2003 - 2005 (RS) Town & Country/Voyager/Caravan 2003 - 2004 (TJ) Wrangler NOTE: Refer to the following table for specific applications. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 4115 DISCUSSION: If the vehicle operator describes a MIL illumination and the technician finds DTC P1776 Solenoid Switch Valve Latched in LR Position is set the DRBIII(R) can be used to access the event data screen and look at the "TRS Code" reading. NOTE: The solenoid switch valve is not in the solenoid pack it is in the valve body. TRS Code Reads TR2 If the TRS Code displays TR2 it is an indication that the manual valve was not fully in the OD position at the time the DTC was set. Check the shifter cable adjustment and adjust if necessary. Also check the shift control system for excessive friction and/or routing issues. TRS Code Reads OD If the "TRS Code displays "OD" then a sticky solenoid switch valve is the primary cause. Perform the proper diagnosis for the valve body. Inspect for foreign material in the solenoid switch valve and plugs. **FOR 2002 - 2004 LH MODEL ONLY** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 4116 **If replacing the valve body assembly for DTC P1776 Solenoid Switch Valve Latched in LR Position first inspect the build date on the solenoid pack (Fig. 1) or (Fig. 2). If the build date range falls in between 3001 and 0603 replace the solenoid pack not the valve body** NOTE: The first three characters are the day of the year, the fourth character is the year, ie. 3001 is the 300th day of 2001. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 4122 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 4128 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4129 Valve Body: Description and Operation 41/40TE - Automatic Transmission VALVE BODY - DESCRIPTION The valve body assembly consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, solenoid/pressure switch assembly, and frictional clutches. The valve body contains the following components (Fig. 307): - Regulator valve - Solenoid switch valve - Manual valve - Converter clutch switch valve - Converter clutch control valve - Torque converter regulator valve - Low/Reverse switch valve In addition, the valve body also contains the thermal valve, # 2, 3 & 4 check balls, the # 5 (overdrive) check valve and the 2/4 accumulator assembly. OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from the pump, which works against spring tension to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid. In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves. MANUAL VALVE The manual valve is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4130 CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve is fed to the torque converter regulator valve, where it passes through the valve, and is slightly regulated. The pressure is then directed to the converter clutch switch valve and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. CONVERTER CLUTCH CONTROL VALVE The converter clutch control valve controls the back (on) side of the torque converter clutch. When the TCM energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under all operating conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal Valve Body: Service and Repair Removal 41TE - Automatic Transmission VALVE BODY - REMOVAL NOTE: If valve body is replaced or reconditioned, the TCM Quick Learn Procedure must be performed. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect gearshift cable from manual valve lever. 4. Remove manual valve lever from manual shaft. 5. Disconnect Transmission Range Sensor (TRS). 6. Raise vehicle on hoist. 7. Remove oil pan bolts (Fig. 308). 8. Remove oil pan (Fig. 309). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4133 9. Remove oil filter (Fig. 310). 10. Remove the valve body-to-transaxle case bolts (Fig. 311). NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise to low or first gear. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4134 11. Remove park rod rollers from guide bracket and remove valve body from transaxle (Fig. 312) (Fig. 313). CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4135 Valve Body: Service and Repair Disassembly 41TE - Automatic Transmission DISASSEMBLY NOTE: If valve body assembly is being reconditioned, the TCM Quick Learn Procedure must be performed. 1. Remove manual shaft seal (Fig. 314). 2. Remove Transmission Range Sensor retaining screw (Fig. 315). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4136 3. Remove Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 316). 4. Remove 2/4 Accumulator Retaining Plate (Fig. 317). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4137 5. Remove 2/4 Accumulator components as shown in (Fig. 318). 6. Remove Valve Body to Transfer Plate screws (Fig. 319). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4138 7. Invert assembly and remove Transfer Plate (Fig. 320). Beware of loose check balls. 8. Remove oil screen (Fig. 321). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4139 9. Remove the overdrive clutch (# 5) check valve (Fig. 322). NOTE: Tag all valve/spring assemblies for reassembly identification. 10. Remove separator plate (Fig. 323). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4140 11. Remove thermal valve (Fig. 324). 12. Remove check balls (Fig. 325). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4141 13. Remove dual retainer plate using Tool 6301 (Fig. 326). 14. Remove regulator valve spring retainer (Fig. 327). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4142 15. Remove remaining retainers as shown in (Fig. 328). 16. Remove valves and springs as shown in (Fig. 329). NOTE: Refer to Valve Body Cleaning and Inspection for cleaning procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4143 Valve Body: Service and Repair Assembly 41TE - Automatic Transmission ASSEMBLY NOTE: If valve body assembly is reconditioned, the TCM Quick Learn Procedure must be performed. 1. Install valves and springs as shown in (Fig. 329). 2. Install regulator valve spring retainer (Fig. 330). 3. Install dual retainer plate using Tool 6301 (Fig. 331). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4144 4. Verify that all retainers are installed as shown in (Fig. 332). Retainers should be flush or below valve body surface. 5. Install check balls into position as shown in (Fig. 333). If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4145 6. Install thermal valve into transfer plate (Fig. 334). 7. Install separator plate to valve body (Fig. 335). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4146 8. Install the overdrive clutch (# 5) check valve to separator plate (Fig. 336). 9. Install oil screen to separator plate (Fig. 337). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4147 10. Install transfer plate to valve body and separator plate. Make sure oil screen and # 5 check valve do not bind (Fig. 338). 11. Install twenty-four transfer plate to valve body screws (Fig. 339) and torque to 5 Nm (45 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4148 12. Install 2/4 Accumulator components as shown in (Fig. 340). 13. Torque 2/4 Accumulator retainer to 5 Nm (45 in. lbs.) (Fig. 341). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4149 14. Install Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 342). 15. Make sure Manual Valve control pin is contained within the rooster comb slot (Fig. 343). Install Transmission Range Sensor retaining screw (Fig. 343) and torque to 5 Nm (45 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4150 16. Install manual shaft seal (Fig. 344). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4151 Valve Body: Service and Repair Installation 41TE - Automatic Transmission INSTALLATION NOTE: If valve body assembly is being replaced or reconditioned, it is necessary to perform the TCM Quick Learn Procedure. 1. Install valve body assembly to transaxle (Fig. 345). Install and torque valve body-to-transaxle case bolts (Fig. 346) to 12 Nm (105 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4152 2. Install transaxle oil filter (Fig. 347). Inspect the O-ring and replace if necessary. 3. Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry. Install an 1/8" bead of Mopar ATF RTV (MS-GF41) to the oil pan and install (Fig. 348). Torque oil pan-to-transaxle case bolts (Fig. 349) to 19 Nm (165 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 4153 4. Lower vehicle. 5. Connect transmission range sensor connector. 6. Install manual valve lever to manual shaft. 7. Install gearshift cable to manual valve lever. 8. Install air cleaner/throttle body assembly. 9. Connect battery negative cable. 10. Fill transaxle with Mopar ATF +4 Transmission fluid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Damper > Component Information > Specifications Clutch Damper: Specifications Damper-to-Transaxle Nuts .................................................................................................................. ................................................ 24 Nm (215 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications Clutch Cover-to-Flywheel Bolts .......................................................................................................................................................... 29 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4161 Clutch Disc: Service and Repair CLUTCH DISC REMOVAL 1. Raise hood. 2. Disconnect and isolate both battery cables, remove battery hold down clamp and bolt, and remove battery. 3. Remove air cleaner/throttle body assy. (Fig. 6) as follows: a. Disconnect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body. b. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. c. Disconnect throttle body air duct at intake manifold. d. Remove mounting bolt and nut (Fig. 6) and partially remove air cleaner assembly. e. Disconnect accelerator and speed control (if equipped) cables after the assy. is removed from position. Remove air cleaner assembly from vehicle. 4. Remove battery tray from bracket. 5. Disconnect ground cable at battery tray bracket. 6. Disconnect back-up lamp switch connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4162 7. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 7) (Fig. 8). 8. Remove shift cable-to-bracket clips (Fig. 9). 9. Disconnect shift selector and crossover cable from levers (Fig. 9). Remove cables and secure out of the way. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4163 10. Disconnect the vehicle speed sensor connector (Fig. 10). 11. Raise vehicle on hoist. 12. Remove transaxle oil drain plug and drain oil into a suitable container. 13. Remove both half shafts. 14. Remove starter motor (Fig. 11). 15. Support engine at oil pan with screw jack and wood block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4164 16. Remove transaxle upper mount thru-bolt. Gain access to this bolt through the driver's side wheel house (Fig. 12). 17. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained. 18. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts. 19. Remove transaxle from vehicle. 20. Remove bolts holding the clutch pressure plate to the flywheel. 21. Remove the clutch pressure plate and disc from the flywheel. 22. Remove the bolts holding the flywheel to the engine crankshaft. 23. Remove the flywheel from the crankshaft. INSTALLATION 1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. 2. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have been removed. 3. Inspect the clutch disc for the side marked "FLYWHEEL SIDE". 4. Apply a very light coating of grease to the splines in the clutch disc hub. 5. Position the flywheel onto the engine crankshaft. 6. Install the bolts to hold the flywheel to the crankshaft. Tighten the bolts to 95 Nm (70 ft. lbs.). 7. Position the clutch disc to the flywheel. 8. Install the clutch pressure plate to the flywheel. Finger tighten the pressure plate bolts. 9. Use Clutch Alignment Tool 6724 to position the clutch disc to the center of the flywheel. 10. Tighten the clutch pressure plate bolts in a criss-cross pattern to 28 Nm (250 inch lbs.). 11. Install transaxle into position. Be sure to carefully guide the input shaft splines through the clutch disc. It may be necessary to slightly rotate the transaxle or flywheel to allow the splines to engage. 12. Install transaxle-to-engine mounting bolts and tighten to 108 Nm (80 ft. lbs.) torque. 13. Raise engine and transaxle with screw jack until through hole in upper mount aligns with hole in mount bracket. Install mount bolt and tighten to 108 Nm (70 ft. lbs.) torque (Fig. 12). 14. Remove screw jack. 15. Install starter motor and tighten bolts to 54 Nm (40 ft. lbs.) torque. Make sure to fasten ground cable to upper starter bolt as shown in (Fig. 11). 16. Connect starter electrical harness and tighten positive cable nut to 10 Nm (90 inch lbs.) torque. 17. Install both front axle driveshafts. 18. Fill transaxle with suitable amount of Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Fill height is 3/16" (4.76 mm) below bottom of fill hole. 19. Lower vehicle. 20. Connect vehicle speed sensor connector (Fig. 10). 21. Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 9). 22. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line. 23. Connect back-up lamp switch connector. 24. Connect ground strap to transaxle upper mount bracket. 25. Install battery lower tray and battery, and tighten battery hold down clamp to secure battery. 26. Install the air cleaner/throttle body assy. as follows: a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assy. b. Install assembly into position, making sure the air cleaner locating slot is engaged to the battery bracket tab, and tighten fasteners to 14 Nm (120 inch lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4165 c. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 Nm (40 inch lbs.) torque. d. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. e. Connect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body. 27. Connect the battery cables. 28. Road test vehicle and inspect for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications HYDRAULIC - FLUID CAUTION: Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system. NOTE: The clutch hydraulic system and replacement components are pre-filled, and under normal operating conditions, additional fluid is not required for the life of the vehicle. The fluid required for use in the clutch hydraulic system is brake fluid conforming to DOT 3 specifications and J1703 standards. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 4171 Clutch Fluid: Fluid Type Specifications HYDRAULIC - FLUID CAUTION: Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system. NOTE: The clutch hydraulic system and replacement components are pre-filled, and under normal operating conditions, additional fluid is not required for the life of the vehicle. The fluid required for use in the clutch hydraulic system is brake fluid conforming to DOT 3 specifications and J1703 standards. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications Clutch Master Cylinder: Specifications Master Cylinder Pushrod Adj. Screw ..................................................................................................................................................... 6 Nm (55 inch lbs.) Master Cylinder Mounting Nuts (LHD) ............................................................................................................................................. 15 Nm (130 inch lbs.) Master Cylinder Reservoir Mounting bolts (LHD) ............................................................................................................................ 11 Nm (100 inch lbs.) Master Cylinder Reservoir Mounting Screw (RHD) .............................................................................................................................. 3 Nm (24 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4175 Clutch Master Cylinder: Description and Operation MASTER CYLINDER - DESCRIPTION (LHD) The LHD clutch master cylinder mounts to the dash panel (Fig. 26). The master cylinder consists of an adjustable push rod, a piston and cylinder housing, a remote fluid reservoir, and an interconnecting hydraulic tube (Fig. 27). MASTER CYLINDER - DESCRIPTION (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4176 The RHD clutch master cylinder (Fig. 28) mounts through the dash panel and to the pedal bracket assembly. The master cylinder consists of a push rod, a piston and cylinder housing, a remote fluid reservoir, and an interconnecting hydraulic tube (Fig. 29). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4177 OPERATION The clutch master cylinder (Fig. 27) (Fig. 29) produces the hydraulic pressure necessary to disengage the clutch. When the clutch pedal is depressed, the push rod moves the piston to produce pressure in the cylinder. This pressure moves fluid through the system to the slave cylinder, which in turn operates the clutch release lever and bearing, disengaging the clutch. When the clutch pedal is released, pressure is relieved and the return spring returns the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4178 piston to its original position until the next pedal actuation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH Clutch Master Cylinder: Service and Repair Master Cylinder - LDH MASTER CYLINDER / REMOVAL - LHD NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the slave cylinder assembly. 1. Remove air cleaner assembly (Fig. 30). 2. Disconnect battery negative cable. 3. Raise vehicle on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH > Page 4181 4. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 32) (Fig. 31). 5. Remove hydraulic hose from left rail retainers (Fig. 35). 6. Lower vehicle. 7. Remove PDC bracket and position out of way. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH > Page 4182 8. Remove lower instrument panel bezel (Fig. 33). 9. Remove clip and disconnect the brake booster input rod from the brake pedal pin (Fig. 34). 10. Remove the brake booster mounting nuts (Fig. 34). 11. Slide brake booster forward enough to gain access to and remove clutch master cylinder. 12. Remove clutch master cylinder reservoir (Fig. 35). 13. Disconnect clutch master cylinder rod from clutch pedal. Inspect plastic retainer. If retainer is broken or damaged in any way, it MUST be replaced upon reassembly. 14. Remove two clutch master cylinder retaining nuts. 15. Remove the self-docking connector bracket. CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly. 16. Remove master cylinder from mounting position and carefully work hydraulic pipe from out of engine compartment (Fig. 35). If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance. INSTALLATION - LHD 1. Install the master cylinder into position on the dash panel. 2. Install the self-docking connector bracket. 3. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 11 Nm (100 inch lbs.). 4. Route the hydraulic tube as noted upon removal. 5. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line. 6. Install the master cylinder remote reservoir onto the dash panel. 7. Install the reservoir retaining screws. Tighten the screws to 11 Nm (103 inch lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH > Page 4183 8. Install the brake booster. CAUTION: Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced. 9. Loosen the push rod adjustment screw (Fig. 40). 10. Install the push rod onto the pedal pin. 11. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.). 12. Install the ABS module/purge solenoid, PDC, and air cleaner. 13. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir. If residual air becomes trapped in the system, bleed the clutch hydraulic system. 14. Connect the negative battery cable. 15. Top off clutch master cylinder reservoir with DOT 3 brake fluid. 16. Verify correct clutch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH > Page 4184 Clutch Master Cylinder: Service and Repair Master Cylinder - RDH MASTER CYLINDER / REMOVAL - RHD NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required. 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 36) and (Fig. 37). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH > Page 4185 4. Remove hydraulic hose (Fig. 38) from the clips along the frame rail and the dash panel. 5. Lower vehicle. 6. Remove the two screws holding the master cylinder remote reservoir to the dash panel. 7. Disconnect the master cylinder push rod from the pedal pin. Inspect plastic retainer. If retainer is damaged in any way, it MUST be replaced. 8. Remove the clutch interlock/upstop switch cover plate and switch housing (Fig. 39) from the master cylinder push rod. 9. From the engine compartment, grasp the master cylinder body and rotate approximately 45° in a counter-clockwise direction. 10. Disengage the master cylinder from the pedal bracket assembly. 11. Remove the master cylinder from the vehicle. INSTALLATION - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Master Cylinder - LDH > Page 4186 1. Install the master cylinder into position on the dash panel. (Fig. 41) 2. Seat the master cylinder in the pedal bracket assembly. 3. Rotate the master cylinder approximately 45° in the clockwise direction. 4. Route the hydraulic tube as noted upon removal. 5. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line. 6. Install the master cylinder remote reservoir onto the dash panel. 7. Install the reservoir retaining screws. Tighten the screws to 3 Nm (24 inch lbs.). 8. Install the clutch interlock/upstop switch and cover plate. (Fig. 42) CAUTION: Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced. 9. Install the push rod onto the pedal pin. 10. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir. If residual air becomes trapped in the system, bleed the clutch hydraulic system. 11. Connect the negative battery cable. 12. Top off clutch master cylinder reservoir with DOT 3 brake fluid. 13. Verify proper clutch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Slave Cylinder-to-Transaxle (2.0L) ......................................................................................................................................................... 19 Nm (14 ft. lbs.) Slave Cylinder-to-Transaxle (1.6L) .................................................................................................................................................... 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4190 Clutch Slave Cylinder: Description and Operation SLAVE CYLINDER - DESCRIPTION The clutch slave cylinder is fastened to transaxle bellhousing (Fig. 54), and consists of a hydraulic piston and cylinder, seal, return spring, and integral fluid damper (if equipped) and line (Fig. 55). OPERATION When the clutch pedal is depressed, fluid pressurized by the clutch master cylinder pushes the slave cylinder piston, extending the push rod and operating the clutch release fork and bearing. The integral damper (Fig. 55) absorbs vibration and noise generated in the clutch release system, preventing it from being transmitted into the passenger compartment via the hydraulic circuit. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4191 Clutch Slave Cylinder: Service and Repair SLAVE CYLINDER - REMOVAL NOTE: Replacement slave cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless excessive air has been introduced to clutch hydraulic circuit. 1. Raise vehicle on hoist. 2. Disconnect clutch hydraulic quick connect using tool 6638A (Fig. 56). 3. 2.0L models: Remove left lateral bending brace. 4. Remove damper bracket nuts (Fig. 57). 5. Remove slave cylinder mounting bolts (Fig. 57). 6. Remove slave cylinder from vehicle. INSTALLATION NOTE: Replacement slave cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4192 system has lost an excessive amount of fluid and has ingested air into the hydraulic circuit. 1. Install the slave cylinder assembly into position on transaxle (Fig. 57). Start damper and slave cylinder fasteners by hand. 2. Tighten slave cylinder bolts-to-transaxle bolts to 19 Nm (168 inch lbs.) on 2.0L applications, and 12 Nm (105 inch lbs.) torque on 1.6L applications. 3. Tighten damper nuts to 24 Nm (215 inch lbs.) torque. 4. Connect clutch hydraulic supply tube (Fig. 57). An audible click should be heard. Verify connection by pulling outward. 5. 2.0L models: Install left lateral bending brace. 6. Lower vehicle. 7. Verify clutch master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary. 8. Actuate clutch pedal a minimum of ten times to allow any air ingested into the system to vent to the master cylinder reservoir. If excessive air is ingested into system, bleed clutch hydraulic system. 9. Verify proper clutch release system operation. 10. If slave cylinder was replaced with a new unit, verify that the shipping strap has been broken. If not, remove straps to prevent high pedal effort. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Brake/Clutch Pedal & Booster-to-Dash Nuts ...................................................................................................................................... 34 Nm (300 inch lbs.) Brake/Clutch Pedal Assembly-to-Instrument Panel ............................................................................................................................ 34 Nm (300 inch lbs.) Clutch Pedal Pivot Shaft Nut ....................................................................................................... ............................................................. 42 Nm (31 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component Locations > Page 4200 Clutch Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component Locations > Page 4201 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component Locations > Page 4202 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4203 Clutch Interlock/Upstop Switch (MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4204 Clutch Switch: Description and Operation CLUTCH INTERLOCK/UPSTOP SWITCH DESCRIPTION - LHD The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 13). The switch assembly is located in the clutch/brake pedal bracket assembly (Fig. 14), each switch being fastened by four plastic wing tabs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4205 DESCRIPTION - RHD The RHD clutch interlock/upstop switch (Fig. 15) consists of a single, multi-function switch that is activated by hydraulic clutch master cylinder push rod travel. OPERATION - CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch pedal in the up position (not depressed), or under normal conditions with the clutch engaged and the transaxle in gear. WARNING: WHEN THERE IS A LOSS OF CLUTCH SYSTEM HYDRAULIC FLUID, OR THE CLUTCH MASTER CYLINDER PUSHROD IS DISCONNECTED FROM THE PEDAL LEVER, THE ENGINE MAY START WITH THE CLUTCH ENGAGED, CAUSING UNDESIRABLE VEHICLE MOVEMENT IF THE TRANSAXLE IS IN ANY GEAR. The switch is open while the clutch pedal is at rest or in the up position. When the clutch pedal is fully depressed on LHD models, the clutch pedal lever closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. When the clutch pedal is fully depressed on RHD models, the master cylinder push rod closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. The interlock switch is not adjustable. OPERATION - CLUTCH PEDAL UPSTOP SWITCH With the clutch pedal at rest, the clutch pedal upstop switch is closed, allowing speed control operation. When the clutch pedal is depressed, the upstop switch opens and signals the PCM to cancel speed control operation, and enter a modified engine calibration schedule to improve driveability during gear-to-gear shifts. The upstop switch is not adjustable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis Clutch Switch: Testing and Inspection Service Diagnosis SERVICE DIAGNOSIS - CLUTCH INTERLOCK/UPSTOP SWITCH The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 4208 The RHD clutch interlock/upstop switch (Fig. 17) consists of a single, multi-function switch that is activated by the hydraulic clutch master cylinder push rod. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 4209 Clutch Switch: Testing and Inspection Clutch Interlock Switch / Mechanical-Electrical Tests CLUTCH INTERLOCK SWITCH Mechanical Test 1. With the park brake set and the transaxle IN NEUTRAL, turn the ignition key to the start position. The engine starter should not crank with the clutch pedal at rest (not depressed). If the starter cranks, proceed to the electrical test to determine whether the switch is defective or the circuit is shorted. If the vehicle does not crank, proceed to the next step. 2. With the park brake set and the transaxle IN NEUTRAL, fully depress the clutch pedal and turn the ignition key to the start position. The engine starter should crank. If the starter does not crank, visually inspect the clutch pedal for obstructions (floor mat, etc.). Make sure the clutch pedal lever contacts and fully closes the switch on LHD applications, and for proper installation of the master cylinder push rod/bushing on the pedal pin on RHD applications. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 2 & 3 (Fig. 18) with the interlock switch not depressed (clutch pedal at rest). There should be no continuity between the terminals (open circuit). 5. LHD Models: Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm (0.050 inch) on LHD applications. The ohmmeter should show continuity (0 ohms resistance). RHD Models: Disconnect the push rod from the pedal pin and actuate the push rod by hand to close the switch. The ohmmeter should show continuity (0 ohms). Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked) it MUST be replaced before reinstalling the push rod to the pedal. 6. If ohmmeter readings do not fall within these ranges, the switch assembly, or the pedal bracket assembly, is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 4210 Clutch Switch: Testing and Inspection Upstop Switch / Mechanical-Electrical Tests UPSTOP SWITCH Mechanical Test 1. Raise vehicle on hoist. 2. Start engine and operate speed control to maintain speed. 3. Depress clutch pedal at least 33 mm (1.30 inch). Speed control operation should terminate. If speed control does not terminate, the upstop switch is defective or the related wiring is shorted. Proceed to the upstop switch electrical test. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 1 & 2 (Fig. 18) with the upstop switch depressed (clutch pedal at rest). The ohmmeter should show continuity (0 ohms). 5. Depress the clutch pedal at least 33 mm (1.30 inch) check for continuity between terminals 1 & 2. There should be no continuity between the terminals (open circuit). 6. If ohmmeter readings do not fall within these ranges, the switch assembly is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - LHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - LHD 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 19). 3. Disconnect upstop switch and brake lamp switch connectors. 4. Disconnect clutch master cylinder rod from clutch pedal pin. Inspect plastic retainer upon removal. If retainer is damaged, it MUST be replaced. 5. Remove brake booster push rod retaining clip from brake pedal. Disengage rod from pedal (Fig. 20). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 4213 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 21). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 21). 8. From under the hood, pull brake master cylinder/booster far enough forward to obtain pedal to bracket stud clearance. 9. Remove the pedal bracket assembly (Fig. 21). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 22) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION - LHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 4214 contacting pedals. 1. Install switches into the pedal bracket assembly as shown in (Fig. 22). Route harness as was prior to removal. Secure switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 42 Nm (31 ft. lbs.). 3. Install brake/clutch pedal bracket assembly into position. Install and tighten brake booster mounting nuts to 34 Nm (25 ft. lbs.). Install and tighten pedal bracket-to-instrument panel nuts to 34 Nm (25 ft. lbs.). 4. Install new stop lamp switch. 5. Connect brake booster rod to brake pedal. Install retainer clip (Fig. 20). 6. Loosen adjustment screw (Fig. 24). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 7. Connect clutch master cylinder pushrod. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.). 8. Connect interlock/upstop and stop lamp switch connectors. 9. Install left lower instrument panel bezel (Fig. 19). 10. Connect battery negative cable. 11. Verify proper switch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 4215 Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - RHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - RHD 1. Disconnect the master cylinder push rod from the pedal pin (Fig. 23). Inspect push rod retainer for damage. If it is damaged (broken/cracked), it must be replaced. 2. Squeeze together the tangs on the switch cover plate and slide the plate off the switch housing. 3. Disconnect the clutch interlock/upstop switch connector from the instrument panel wiring harness. 4. Remove the switch from the vehicle. INSTALLATION - RHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals. 1. Install the clutch interlock/upstop switch onto the master cylinder push rod, making sure that the push rod is oriented with the push rod retainer toward the wiring of the switch. The master cylinder push rod must be snapped into the clutch interlock/upstop switch along the smaller diameter of the push rod between the snap ring and the transition to the larger diameter. CAUTION: Improper assembly of the larger diameter of the push rod into the clutch interlock/upstop switch could cause damage to the switch or a clutch system failure. 2. Install the switch cover plate. CAUTION: Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked), it MUST be replaced. 3. Connect clutch master cylinder pushrod to the clutch pedal pin. 4. Route the wiring harness as it was prior to removal. 5. Secure the switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 RELEASE BEARING AND LEVER - DESCRIPTION A conventional release bearing is used to engage and disengage the clutch pressure plate. The clutch release bearing is mounted on the transaxle front bearing retainer. The bearing is attached to and operated by the release lever (Fig. 25), which moves the bearing into contact with the clutch cover diaphragm spring. OPERATION The release bearing is operated by the release lever. Slave cylinder force causes the release lever to move the release bearing into contact with the diaphragm spring. As additional force is applied, the bearing presses the diaphragm spring fingers inward on the fulcrums. This action moves the pressure plate rearward, relieving clamping force on the clutch disc. Releasing pedal pressure removes clutch hydraulic pressure. The release bearing then moves away from the diaphragm spring which allows the pressure plate to exert clamping force on the clutch disc. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Description and Operation > Page 4219 Clutch Release Bearing: Service and Repair RELEASE BEARING AND LEVER REMOVAL 1. Remove the transaxle from the vehicle. 2. 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. 3. As a unit, remove the lever from the bearing thrust plate. Be careful not to damage retention tabs on bearing. 4. Examine the condition of the bearing. It is pre-lubricated and sealed and should not be immersed in oil or solvent. 5. 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. 6. Check the condition of the pivot stud spring clips on back side of clutch lever. If the clips are broken or distorted, replace the clutch lever. INSTALLATION 1. The pivot ball pocket in the lever, as well as the lever arms should be lubricated with grease prior to installation. 2. Assemble the lever to the bearing. The small pegs on the bearing must go over the lever arms. 3. Slide the bearing and lever assembly onto the input shaft bearing retainer, as a unit. 4. Snap the clutch lever onto the pivot ball. 5. Reinstall transaxle assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair T350 Manual Transaxle INPUT BEARING AND SLEEVE - REMOVAL The input bearing is a one-piece bearing and sleeve unit (Fig. 107). The sleeve is the slide point for the clutch-release bearing and lever. 1. Install tool #6342 over input bearing on the gear case side of the transaxle clutch housing. 2. Press the input bearing out of the housing (Fig. 108). INSTALLATION 1. Apply coating of Loctite sealant on bearing outer diameter. Position sleeve and bearing assembly at input bearing bore. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 4223 2. Install tool #C-4680-1 over input bearing (Fig. 109). 3. Using the spacer tool #4894 and shop press, install input bearing into bore until it is fully seated (Fig. 110). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound Technical Service Bulletin # 03-006-04 Date: 040915 Drivetrain - Front Hub/Half Shaft Pop/Click Sound NUMBER: 03-006-04 GROUP: Axle and Propshaft DATE: September 15, 2004 SUBJECT: Front Hub/Half Shaft Click/Pop Sound OVERVIEW: This bulletin involves installing a rubber gasket to the face of the half shaft that mounts to the hub bearing. MODELS: 2000 - 2005 (PL) Neon 2001 - 2004 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to PT vehicles built prior to February 18, 2004, (MDH 0218XX). SYMPTOM/CONDITION: Vehicle may exhibit a popping/clicking/snapping/ticking sound from the front hub/half shaft area during acceleration after Drive to Reverse or Reverse to Drive shifts. The sound may also be present while turning and accelerating from a stop. DIAGNOSIS: In order to determine if the popping/clicking/snapping/ticking sound is coming from the front hub/half shaft interface, perform the following procedure: 1. Raise the vehicle on an appropriate hoist and remove both front wheels. 2. Remove the cotter pin, nut lock, and wave washer from the end of both front half shafts. 3. With the vehicle's brakes applied to keep hub from turning, loosen both half shaft nuts to zero torque. 4. With the service brake applied, shift the vehicle from Drive to Reverse and Reverse to Drive. Once the transmission is engaged in gear, raise the engine speed to 1800 rpm. 5. If the sound is not present, perform the Repair Procedure. If the sound is still present, the source of the sound is elsewhere. Further diagnosis is required. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4234 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle. 2. Remove the half shaft nut. 3. Remove the wheel and tire assembly from the vehicle. Refer to the service information available in TechCONNECT Section 22. 4. Remove the two front disc brake caliper adapter to steering knuckle attaching bolts (Fig. 1). 5. Remove the disc brake caliper assembly from the steering knuckle. The caliper assembly is removed by first rotating the top of the caliper assembly away from the steering knuckle and then removing the bottom of the assembly out from under the machined abutment on the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4235 6. Support the disc brake caliper assembly by using a wire hook and suspending it from the strut assembly (Fig. 2). NOTE: Do not allow the brake caliper assembly to hang by the brake flex hose. 7. Remove the brake rotor from the hub and bearing assembly. 8. If the vehicle is equipped with eccentric bolts attaching the steering knuckle to the strut assembly, proceed to next step. If not, proceed to step 10. 9. Mark the head of the eccentric bolt and the strut, so that the bolt can be installed in the same position later. 10. Remove the wheel speed sensor bolt. 11. Remove the steering knuckle-to-strut attachment bolts from the steering knuckle (Fig. 3). 12. Pull the steering knuckle from the strut clevis bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4236 NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow half shaft to hang by inner C/V joint after removing outer C/V joint from the hub/bearing assembly in steering knuckle, the outboard end of the half shaft must be supported. 13. Pull the steering knuckle assembly down and away from the outer C/V joint while pulling the C/V joint out of the hub bearing. 14. Support the outer end of the half shaft assembly. NOTE: The rubber gasket is to be installed as is (after removing the paper backing). The gasket should not be cut in any way. 15. Peel paper backing off of the gasket. Slide the gasket over the C/V joint splines with the adhesive side of the gasket facing the C/V joint surface, item 2, shown in (Fig. 4). 16. Grasp the inner tripod joint and interconnecting shaft. Forcefully push the tripod joint into side gear of the transaxle, be sure the snap-ring is engaged with the transaxle side gear. 17. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint will be installed into steering knuckle. 18. Clean the C/V joint surface. 19. Ensure that the front of the outer CV joint which fits against the face of the hub and bearing is free of debris and moisture before installing the outer CV joint into the hub and bearing assembly. 20. Slide the half shaft back into the front hub and bearing assembly. 21. Install the wheel speed sensor bolt and torque it to 12 Nm (105 in. 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 knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4237 CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 5). 22. Install the steering knuckle in the clevis bracket of the strut assembly. Install the strut to steering knuckle attaching bolts. If the eccentric bolt and strut was marked in step 9, align the marks. Tighten both bolts to a torque of 88 Nm (65 ft.lbs.) plus an additional 1/4 turn. 23. Install the brake rotor on the hub and bearing assembly. 24. Install the disc brake caliper assembly on the steering knuckle. The caliper is installed by first sliding the bottom of the caliper assembly under the abutment on the steering knuckle, and then rotating the top of the caliper against the top abutment. 25. Install the disc brake caliper adapter to steering knuckle attaching bolts (Fig. 1). Tighten the disc brake caliper adapter attaching bolts to a torque of 169 Nm (125 ft. lbs.). 26. Clean all foreign matter from the threads of the outer CV joint. Install the washer and half shaft nut on half shaft and securely tighten the nut (the nut will be torqued later). 27. Install the front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all the nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft.lbs.). 28. Repeat steps 2 through 27 on the other side of the vehicle. When steps 2 through 25 have been completed on both sides of the vehicle, lower the vehicle. 29. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 Nm (180 ft.lbs.) 30. Install the spring wave washer on the end of the half shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4238 31. Install the hub nut lock, and a new cotter pin. Wrap the cotter pin prongs tightly around the hub nut lock as shown in (Fig. 6). 32. Repeat steps 29 through 31 on the other side of the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound Technical Service Bulletin # 03-006-04 Date: 040915 Drivetrain - Front Hub/Half Shaft Pop/Click Sound NUMBER: 03-006-04 GROUP: Axle and Propshaft DATE: September 15, 2004 SUBJECT: Front Hub/Half Shaft Click/Pop Sound OVERVIEW: This bulletin involves installing a rubber gasket to the face of the half shaft that mounts to the hub bearing. MODELS: 2000 - 2005 (PL) Neon 2001 - 2004 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to PT vehicles built prior to February 18, 2004, (MDH 0218XX). SYMPTOM/CONDITION: Vehicle may exhibit a popping/clicking/snapping/ticking sound from the front hub/half shaft area during acceleration after Drive to Reverse or Reverse to Drive shifts. The sound may also be present while turning and accelerating from a stop. DIAGNOSIS: In order to determine if the popping/clicking/snapping/ticking sound is coming from the front hub/half shaft interface, perform the following procedure: 1. Raise the vehicle on an appropriate hoist and remove both front wheels. 2. Remove the cotter pin, nut lock, and wave washer from the end of both front half shafts. 3. With the vehicle's brakes applied to keep hub from turning, loosen both half shaft nuts to zero torque. 4. With the service brake applied, shift the vehicle from Drive to Reverse and Reverse to Drive. Once the transmission is engaged in gear, raise the engine speed to 1800 rpm. 5. If the sound is not present, perform the Repair Procedure. If the sound is still present, the source of the sound is elsewhere. Further diagnosis is required. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4244 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle. 2. Remove the half shaft nut. 3. Remove the wheel and tire assembly from the vehicle. Refer to the service information available in TechCONNECT Section 22. 4. Remove the two front disc brake caliper adapter to steering knuckle attaching bolts (Fig. 1). 5. Remove the disc brake caliper assembly from the steering knuckle. The caliper assembly is removed by first rotating the top of the caliper assembly away from the steering knuckle and then removing the bottom of the assembly out from under the machined abutment on the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4245 6. Support the disc brake caliper assembly by using a wire hook and suspending it from the strut assembly (Fig. 2). NOTE: Do not allow the brake caliper assembly to hang by the brake flex hose. 7. Remove the brake rotor from the hub and bearing assembly. 8. If the vehicle is equipped with eccentric bolts attaching the steering knuckle to the strut assembly, proceed to next step. If not, proceed to step 10. 9. Mark the head of the eccentric bolt and the strut, so that the bolt can be installed in the same position later. 10. Remove the wheel speed sensor bolt. 11. Remove the steering knuckle-to-strut attachment bolts from the steering knuckle (Fig. 3). 12. Pull the steering knuckle from the strut clevis bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4246 NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow half shaft to hang by inner C/V joint after removing outer C/V joint from the hub/bearing assembly in steering knuckle, the outboard end of the half shaft must be supported. 13. Pull the steering knuckle assembly down and away from the outer C/V joint while pulling the C/V joint out of the hub bearing. 14. Support the outer end of the half shaft assembly. NOTE: The rubber gasket is to be installed as is (after removing the paper backing). The gasket should not be cut in any way. 15. Peel paper backing off of the gasket. Slide the gasket over the C/V joint splines with the adhesive side of the gasket facing the C/V joint surface, item 2, shown in (Fig. 4). 16. Grasp the inner tripod joint and interconnecting shaft. Forcefully push the tripod joint into side gear of the transaxle, be sure the snap-ring is engaged with the transaxle side gear. 17. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint will be installed into steering knuckle. 18. Clean the C/V joint surface. 19. Ensure that the front of the outer CV joint which fits against the face of the hub and bearing is free of debris and moisture before installing the outer CV joint into the hub and bearing assembly. 20. Slide the half shaft back into the front hub and bearing assembly. 21. Install the wheel speed sensor bolt and torque it to 12 Nm (105 in. 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 knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4247 CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 5). 22. Install the steering knuckle in the clevis bracket of the strut assembly. Install the strut to steering knuckle attaching bolts. If the eccentric bolt and strut was marked in step 9, align the marks. Tighten both bolts to a torque of 88 Nm (65 ft.lbs.) plus an additional 1/4 turn. 23. Install the brake rotor on the hub and bearing assembly. 24. Install the disc brake caliper assembly on the steering knuckle. The caliper is installed by first sliding the bottom of the caliper assembly under the abutment on the steering knuckle, and then rotating the top of the caliper against the top abutment. 25. Install the disc brake caliper adapter to steering knuckle attaching bolts (Fig. 1). Tighten the disc brake caliper adapter attaching bolts to a torque of 169 Nm (125 ft. lbs.). 26. Clean all foreign matter from the threads of the outer CV joint. Install the washer and half shaft nut on half shaft and securely tighten the nut (the nut will be torqued later). 27. Install the front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all the nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft.lbs.). 28. Repeat steps 2 through 27 on the other side of the vehicle. When steps 2 through 25 have been completed on both sides of the vehicle, lower the vehicle. 29. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 Nm (180 ft.lbs.) 30. Install the spring wave washer on the end of the half shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 03-006-04 > Sep > 04 > Drivetrain - Front Hub/Half Shaft Pop/Click Sound > Page 4248 31. Install the hub nut lock, and a new cotter pin. Wrap the cotter pin prongs tightly around the hub nut lock as shown in (Fig. 6). 32. Repeat steps 29 through 31 on the other side of the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4249 Axle Shaft: Service and Repair HALFSHAFT 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 halfshaft to prevent damage. The halfshaft, 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 halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. 1. Disconnect battery negative cable. 2. Place transaxle in gated park. 3. Raise vehicle on hoist. 4. Remove wheel and tire assembly (Fig. 1). 5. Remove the halfshaft to hub cotter pin, nut lock, wave washer and hub nut (Fig. 2). 6. If equipped with ABS, disconnect the front wheel speed sensor and secure harness out of the way. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4250 7. Remove nut and bolt (Fig. 3) retaining ball joint stud into steering knuckle. CAUTION: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged. 8. Separate ball joint stud from steering knuckle by prying down on lower control arm (Fig. 4). CAUTION: Care must be taken not to separate the inner C/V joint during this operation. Do not allow halfshaft to hang by inner C/V joint, halfshaft must be supported. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4251 9. Remove halfshaft from steering knuckle by pulling outward on knuckle while pressing in on halfshaft. Support outer end of halfshaft assembly. If difficulty in separating halfshaft from steering knuckle is encountered, use Puller 1026 as shown in (Fig. 5) to separate shaft. Do not strike shaft with hammer. 10. Support outer end of the halfshaft assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4252 11. 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 punch against the inner tripod joint (Fig. 6). 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 (Fig. 7). Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear. 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. 12. Hold inner tripod joint and interconnecting shaft of halfshaft assembly (Fig. 8). 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. When tripod joint is removed from transaxle, some fluid will leak out. CAUTION: The halfshaft, 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 halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. INSTALLATION CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4253 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 halfshaft to prevent damage. 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 halfshaft 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 halfshaft 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 (Fig. 9). 5. Ensure that front of outer C/V joint, which fits into steering knuckle (Fig. 10) is free of debris and moisture before assembling into steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4254 6. Slide halfshaft back into front hub. Install steering knuckle onto the ball joint stud (Fig. 11). NOTE: At this point, the outer joint will not seat completely into the front hub. The outer joint will be pulled into hub and seated when the hub nut is installed and torqued. 7. Install a NEW steering knuckle to ball joint stud bolt and nut (Fig. 11). Tighten the nut and bolt to 95 Nm (70 ft. lbs.). 8. Clean all foreign matter from threads of halfshaft outer stub axle. Install hub nut onto the threads of the stub axle and tighten nut to 244 Nm (180 ft. lbs.) (Fig. 12). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 4255 9. Install front wheel and tire assembly. Install front wheel lug nuts (Fig. 13) and tighten to 128 Nm (95 ft. lbs.). 10. Check for correct fluid level in transaxle assembly. 11. Lower vehicle. 12. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner Constant Velocity Joint Boot: Service and Repair CV Boot - Inner CV BOOT - INNER / REMOVAL To remove sealing boot from halfshaft for replacement, the halfshaft 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 halfshaft requiring boot replacement from the vehicle. 2. Remove large boot clamp that retains inner tripod joint sealing boot to tripod joint housing (Fig. 14) 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 (Fig. 15). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4260 4. Remove snap ring that retains spider assembly to interconnecting shaft (Fig. 16). 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 (Fig. 17). 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 halfshaft assembly will require replacement. Component parts of these halfshaft 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4261 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 (Fig. 18). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4262 2. Install spider assembly onto interconnecting shaft with chamfer on spider assembly toward interconnecting shaft (Fig. 19). 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 (Fig. 20). 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 (Fig. 21). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4263 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 22). 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4264 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 (Fig. 23). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 24). 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. CAUTION: 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. 9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly (Fig. 25). 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4265 10. With trim stick inserted between sealing boot and tripod joint housing, position inner tripod joint on halfshaft until correct sealing boot edge to edge length is obtained for type of sealing boot material being used (Fig. 26) (Fig. 27). Then remove the trim stick. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4266 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 (Fig. 28). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face-to-face (Fig. 29). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4267 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 (Fig. 30). Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 31). 13. Install the halfshaft requiring boot replacement back on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4268 Constant Velocity Joint Boot: Service and Repair CV Boot - Outer CV BOOT - OUTER / REMOVAL 1. Remove halfshaft assembly requiring boot replacement from vehicle. 2. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing (Fig. 32) 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 (Fig. 33). Then slide outer C/V joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4269 5. Remove large circlip (Fig. 34) from the interconnecting shaft before attempting to remove outer C/V joint sealing boot. 6. Slide 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 halfshaft assembly will require replacement. Component parts of these halfshaft 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 (Fig. 35). 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4270 3. Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced hammer and tapping end of stub axle (with hub nut installed) until outer C/V joint is fully seated on interconnecting shaft (Fig. 36). 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 (Fig. 37). 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot. 6. Install outer C/V joint sealing boot to interconnecting shaft clamp evenly on sealing boot. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4271 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 (Fig. 38). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 39). 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 C/V joint retaining clamp evenly on sealing boot. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot - Inner > Page 4272 9. Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp (Fig. 40). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 41). 10. Install the halfshaft requiring boot replacement back on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Bearing Retainer Plate Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Rear To Knuckle Retaining Nut .................................................................................................................... ............................................ 217 Nm (160 ft. lbs.) Wheel Mounting Nuts .......................................................................................................................................................... 109-150 Nm (80-110 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Driveshaft Hub Nut .............................................................................................................................. ............................................ 244 Nm (180 ft. lbs.) Wheel Mounting Nuts ............................................ ........................................................................................................................... 135 Nm (100 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flex Plate to Crankshaft 70 ft.lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4283 Flex Plate: Service and Repair REMOVAL 1. Remove the transaxle. 2. Remove the flex plate attaching bolts (Fig. 79). 3. Remove the flex plate (Fig. 79). INSTALLATION 1. Position the drive plate on crankshaft (Fig. 79). 2. Apply Mopar Lock & Seal Adhesive to flex plate bolt threads. 3. Install the flex plate bolts and tighten to 95 Nm (70 ft. lbs.) (Fig. 79). 4. Install the transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel-to-Crankshaft Bolts ............................................................................................................... .................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams Shift Indicator: Diagrams Trans Range Indicator Illumination (PRNDL)(Autostick) Trans Range Indicator Illumination (PRNDL) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Application and ID Transmission Mode Indicator - A/T: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Console Gear Selector w/ Auto ........................................................................................................... .............................................................. PC 194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Transaxle Case Bolts .......................................................................................................................... ...................................................... 29 Nm (21 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Specifications > Capacity Specifications Differential Fluid - M/T: Capacity Specifications Type ................................................................................................................................. Mopar ATF +4 (Automatic Transmission Fluid - Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. NOTE: The 41TE Automatic and T350 Manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4304 Differential Fluid - M/T: Fluid Type Specifications Type ................................................................................................................................. Mopar ATF +4 (Automatic Transmission Fluid - Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. NOTE: The 41TE Automatic and T350 Manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Specifications Ring Gear: Specifications Differential Ring Gear Bolts ................................................................................................................. .................................................... 81 Nm (60 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications T350 - Manual Transmission Drain Plug ............................................................................................................................................ .............................................. 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications > Page 4311 T350 - Manual Transmission Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Locations T350 - Manual Transmission Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications FLUID CAPACITY NV T350 Manual Transaxle ...................................................................................................................................................... 2.4 - 2.7Liters (2.5 - 2.8 Qt) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4319 Fluid - M/T: Fluid Type Specifications Type ..................................................................................................................................................... ..................................... Mopar ATF +4 (Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Standard Procedure - Fluid Drain and Fill Fluid - M/T: Service and Repair Standard Procedure - Fluid Drain and Fill T350 - Manual Transmission STANDARD PROCEDURE - FLUID DRAIN AND FILL NOTE: The fluid required in this transaxle is Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). T350 - Manual Transmission All T350 transaxles are equipped with a fill plug. The fill plug is located on the left side of the transaxle differential area (Fig. 92). The fluid level should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when checking). T350 - Manual Transmission All T350 transaxles are equipped with a drain plug. The drain plug is located on the lower right side of the transaxle differential housing (Fig. 93). Tighten drain plug to 28 Nm (250 inch lbs.). Fill transaxle to capacity. Refer to chart shown. Wipe the outside of the transaxle if any lubricant spills. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Standard Procedure - Fluid Drain and Fill > Page 4322 Fluid - M/T: Service and Repair Standard Procedure - Fluid Level Check Fluid Level Check Check the fluid level by removing the fill plug. The fluid level should be between the bottom of the fill hole and a point not more than 3/16" (4.76 mm) below the bottom of the hole. Add fluid, if necessary, to maintain the proper level. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Component Information > Service and Repair Gear: Service and Repair T350 - Manual Transmission SYNCHRONIZER DISASSEMBLY Place synchronizer in a clean shop towel and wrap. Press on inner hub. Carefully open up shop towel and remove springs, balls, keys, hub, and sleeve. CLEANING Do not attempt to clean the blocking rings in solvent. The friction material will become contaminated. Place synchronizer components in a suitable holder and clean with solvent. Air dry. INSPECTION Proper inspection of components involve: - Teeth, for wear, scuffed, nicked, burred, or broken teeth - Keys, for wear or distortion - Balls and springs, for distortion, cracks, or wear If any of these conditions exist in these components, replace as necessary. ASSEMBLY 1. Position synchronizer hub onto a suitable holding fixture (input shaft). The synchronizer hubs are directional. The hubs must be installed with the U facing upward. 2. Install springs into hub slot (Fig. 147). 3. Insert key into hub and spring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Component Information > Service and Repair > Page 4326 4. Apply petroleum jelly to the hole in the key. Insert balls into each key (Fig. 148). 5. Slide sleeve over the hub and depress balls as you carefully slip the sleeve into position (Fig. 149). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Component Information > Service and Repair > Page 4327 6. Line up stop ring tang over the keys in the hub (Fig. 150). Install stop rings. Center the keys and balls by pushing on both stop rings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly Input Shaft: Service and Repair Disassembly T350 - Manual Transmission INPUT SHAFT DISASSEMBLY Before disassembly of the input shaft, it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears. The correct gaps are listed below: 1st ............................................................................................................................. ............................................... 0.522 - 2.208 mm (0.021 - 0.087 inch). 2nd ........................................ .................................................................................................................................. 0.522 - 2.208 mm (0.021 - 0.087 inch). 3rd ............................................................................................................... ................................................................ 0.73 - 1.53 mm (0.029 - 0.060 inch). 4th ............................ ................................................................................................................................................... 0.77 1.57 mm (0.030 - 0.062 inch). 5th ....................................................................................................... ........................................................................ 0.73 - 1.53 mm (0.029 - 0.060 inch). If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced. The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly (Fig. 111). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4332 1. Install bearing splitter behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft (Fig. 112). 2. Remove synchronizer and gear using shop press (Fig. 113). 3. Remove caged needle bearing (Fig. 114). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4333 4. Remove 4-5 gears split thrust washer ring (Fig. 115). 5. Remove split thrust washer (Fig. 116). 6. Remove split thrust washer separation pin (Fig. 117). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4334 7. Remove 4th sear (Fig. 118). 8. Remove 4th gear caged needle bearing (Fig. 119). Check the caged needle bearing for a broken retention spring. 9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring (Fig. 120). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4335 10. Install input shaft in shop press. Using bearing splitter, remove 3-4 synchronizer and 3rd gear (Fig. 121). 11. Remove 3rd gear caged needle bearing (Fig. 122). Inspect needle bearing for a broken retention spring. 12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4336 Input Shaft: Service and Repair Assembly T350 - Manual Transmission INPUT SHAFT ASSEMBLY The snap rings that are used on the input shaft are available in select fit sizes. Use the thickest snap ring that fits in each snap ring groove. 1. Place input shaft into shop press. 2. Install 3rd gear caged needle bearing (Fig. 123). 3. Install 3rd gear and 3-4 synchronizer onto input shaft. Install Tool #C-3717 over input shaft and press on synchronizer hub and 3rd gear (Fig. 124). The synchronizer hub has the letter U stamped on the top face of the hub. This designates that the hub must be installed with the U facing upward. 4. Install 3-4 synchronizer snap ring into slot on input shaft. 5. Install blocking ring into 3-4 synchronizer. Install 4th gear caged needle bearing. 6. Install 4th gear onto input shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4337 7. Install 4-5 split thrust washer separation pin (Fig. 125). 8. Install split thrust washer onto input shaft (Fig. 126). 9. Install split thrust washer retaining ring (Fig. 127). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4338 10. Install 5th gear caged needle bearing (Fig. 128). 11. Using special tool #C-3717, install 5th speed gear and synchronizer (Fig. 129). The 5th gear synchronizer hub has the letter S stamped on the top face of the hub. This designates that the hub must be installed with the S facing upward. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 4339 12. Install 5th gear synchronizer snap ring (Fig. 130). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair Output Shaft: Service and Repair T350 - Manual Transmission OUTPUT SHAFT DISASSEMBLY CAUTION: The output shaft is serviced as an assembly. Do not try to repair any component on the output shaft. If the 1-2 synchronizer or gear fails, it is necessary to replace the output shaft assembly. It is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears. The correct gaps are listed below: 1st ........................................................................................................................................................ .......... 0.522 - 2.208 mm (0.021 - 0.087 inch) 2nd .............................................................................. ................................................................................... 0.522 - 2.208 mm (0.021 - 0.087 inch) 3rd ...... .............................................................................................................................................................. .. 0.73 - 1.53 mm (0.029 - 0.060 inch) 4th ........................................................................................... ........................................................................... 0.77 - 1.57 mm (0.030 - 0.062 inch) 5th .................. .................................................................................................................................................... 0.73 - 1.53 mm (0.029 - 0.060 inch) If a stop ring gap does not fall within the specifications it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced. The output shaft incorporates the 1st and 2nd gears and synchronizers on the assembly (Fig. 135). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Specifications Output Shaft Bearing: Specifications Output Bearing Race Ret. Strap ............................................................................................................................................................ 11 Nm (96 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Specifications > Page 4346 Output Shaft Bearing: Service and Repair T350 - Manual Transmission OUTPUT BEARING AND RACE REMOVAL CAUTION: The position of the output shaft bearing is critical. The bearing is not identical end-to-end. Install bearing with larger diameter cage ring facing out. 1. Remove caged roller bearing from output bearing race (Fig. 131). 2. Remove screws at output bearing retainer strap (Fig. 132). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Specifications > Page 4347 3. Install tool #6787 and slide hammer (Fig. 133). Tighten tool to output bearing race. 4. Using slide hammer, remove output bearing race. INSTALLATION 1. Line up output bearing race to race bore. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Specifications > Page 4348 2. Insert tool #4628 with C-4171 into output bearing race (Fig. 134). Tap race into bore. Install output bearing into race. Verify that the larger diameter cage is facing outward. Position bearing retaining strap. Tighten bolts to 11 Nm (96 inch lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Specifications Reverse Idler Gear: Specifications Reverse Idler Shaft Bolt ....................................................................................................................... .................................................... 29 Nm (19 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Shift Shaft Seals Seals and Gaskets: Service and Repair Shift Shaft Seals T350 - Manual Transmission SHIFT SHAFT SEALS REMOVAL It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals. 1. Using a pick tool, pry up on the shift shaft seal, and remove seal from bore. INSTALLATION 1. Position new shift shaft seal into bore. 2. Install shift shaft seal into bore using an appropriate size deep-well socket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Shift Shaft Seals > Page 4356 Seals and Gaskets: Service and Repair Axle Seal T350 - Manual Transmission AXLE SEAL REMOVAL 1. Remove axle shaft. 2. Insert a flat-blade pry tool at outer edge of axle shaft seal (Fig. 66) 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 and insert into axle shaft seal bore. 4. Tap seal into position until seated against transaxle case. 5. Install axle shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor ......................................................................................................................... ..................................................... 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4361 Transmission Speed Sensor: Description and Operation T350 - Manual Transmission DESCRIPTION - VEHICLE SPEED SENSOR 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4362 Transmission Speed Sensor: Service and Repair T350 - Manual Transmission VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector (Fig. 151). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt (Fig. 151). 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. Install pinion gear to speed sensor (Fig. 151). 2. Using a NEW O-ring, install the speed sensor to the transaxle (Fig. 151). 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector (Fig. 151). 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair Shifter M/T: Service and Repair T350 - Manual Transmission SHIFT MECHANISM REMOVAL 1. Lift up on gearshift boot to disengage retainer tabs from console. 2. Push down on knob and rotate clockwise to remove knob/boot assembly (Fig. 139). 3. Remove the center console assembly as shown in (Fig. 140). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Page 4366 4. Remove crossover cable retaining clip and disconnect from shift lever (Fig. 141). 5. Remove selector cable retaining clip and disconnect from shift lever (Fig. 142). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Page 4367 6. Remove four shifter assy.-to-floor pan nuts and remove shifter from vehicle (Fig. 143). INSTALLATION 1. Install shifter assy. to floor pan (Fig. 143). Install and tighten four nuts to 12 Nm (105 inch lbs.) torque. 2. Install selector cable to shifter lever and secure cable to shifter bracket. Install clip (Fig. 142). 3. Install crossover cable to shifter lever and secure cable to shifter bracket. Install clip (Fig. 141). 4. Install center console assembly (Fig. 140). 5. Install knob/boot assembly to shifter lever, align knob to three o'clock position, push knob down to engage spring and rotate counter clockwise. 6. Locate boot to console at forward tab and secure to console with retaining tabs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Selector Shaft: Service and Repair Shift Selector Shaft T350 - Manual Transmission SHIFT SELECTOR SHAFT REMOVAL 1. Disassemble transaxle. 2. With the transaxle disassembled, remove the selector shaft by pushing on the shaft from the outside. Pull shaft out from the inside. INSTALLATION 1. Pull selector shaft into position from the outside. 2. Assemble transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft > Page 4373 Selector Shaft: Service and Repair Shift Selector Shaft Bushing T350 - Manual Transmission SHIFT SELECTOR SHAFT BUSHING REMOVAL 1. Remove selector shaft. 2. Thread tool #6786 into bushing. 3. Install slide hammer #3752 onto tool and remove bushing using slide hammer. (Fig. 145). INSTALLATION 1. Position replacement bushing over selector shaft bore. 2. Using an appropriate size deep-well socket, install bushing in selector shaft bore (Fig. 146). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair Shift Boot: Service and Repair T350 - Manual Transmission GEAR SHIFT KNOB/BOOT ASSEMBLY REMOVAL 1. Disengage boot from console by lifting up to free retaining tabs. 2. Push down on knob and rotate clockwise to remove (Fig. 106). INSTALLATION 1. Install knob/boot assembly to shifter lever, align knob to three o'clock position, push knob down to engage spring and rotate counter clockwise. 2. Locate boot to console at forward tab and secure to console with retaining tabs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications Shift Cable: Specifications Shift Cable Bracket to Transaxle ......................................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4380 Shift Cable: Adjustments T350 - Manual Transmission GEAR SHIFT CABLE - ADJUSTMENTS NOTE: Only the crossover cable is adjustable. The selector cable does not have adjustment capabilities. 1. Disengage gearshift boot retaining tabs to free it from console. 2. Push down on knob and rotate clockwise to remove shifter boot/knob assembly (Fig. 103). 3. Remove the center console assembly as shown in (Fig. 104) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4381 4. Loosen crossover adjustment screw at shifter assembly (Fig. 105). 5. The gearshift mechanism and transaxle crossover lever are spring-loaded and self-centering. Alignment pins used in the past are not required anymore. Allow gearshift mechanism and transaxle crossover lever to relax in their neutral positions. To ensure the gearshift lever is in the proper position, place the shifter in 3rd or 4th gear if necessary. Torque adjustment screw to 8 Nm (70 inch lbs.). Care must be taken to avoid moving the shift mechanism off-center during screw tightening. 6. Install center console assembly (Fig. 104). 7. Install knob/boot assembly to shifter lever, align knob to three o'clock position, push knob down to engage spring and rotate counter clockwise. 8. Secure boot retaining tabs to console. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4382 Shift Cable: Service and Repair T350 - Manual Transmission GEAR SHIFT CABLE REMOVAL NOTE: The crossover and selector cables are manufactured as a cable "assembly" and cannot be serviced individually. 1. Raise hood and disconnect battery negative cable. 2. Disengage gearshift boot from center console. 3. Push down on knob and rotate clockwise to remove gearshift boot/knob assy. (Fig. 94). 4. Remove the center console assembly as shown in (Fig. 95). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4383 5. Remove crossover cable retaining clip and disconnect from shift lever (Fig. 96). 6. Remove selector cable retaining clip and disconnect from shift lever (Fig. 97). 7. Remove three grommet plate-to-floor pan attaching nuts (Fig. 96). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4384 8. Remove air cleaner/throttle body assy. (Fig. 98) as follows: a. Disconnect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body. b. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. c. Disconnect throttle body air duct from intake manifold. d. Remove mounting bolt and nut (Fig. 98) and partially remove air cleaner assembly. e. Disconnect accelerator and speed control (if equipped) cables after the assy. is removed from position. Remove air cleaner assembly from vehicle. 9. Disconnect cables from the shift levers at the transaxle (Fig. 99). CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. Remove cable retaining clips and remove cables from bracket (Fig. 99). 10. Raise vehicle on hoist. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4385 11. Remove converter heat shield (Fig. 100). 12. Remove remaining grommet plate-to-floor pan screw (Fig. 101). 13. Remove cable assembly from vehicle. INSTALLATION NOTE: The crossover and selector cables are manufactured as a cable "assembly" and cannot be serviced individually. CAUTION: Gearshift cable bushings must not be lubricated or the bushings will swell and split. 1. Raise vehicle on hoist. 2. Install cable assembly through floor pan opening and secure to floor pan with grommet plate and one screw (Fig. 101). Make sure the three grommet plate studs protrude through cable assembly and floor pan and tighten screw to 7 Nm (60 inch lbs.). 3. Route transaxle end of cable assembly into engine compartment and over transaxle assembly. 4. Install converter heat shield (Fig. 100). 5. Lower vehicle. 6. Install gearshift cables to mounting bracket and fasten with NEW clips (Fig. 99). Make sure clips are installed flush to bracket. 7. Connect gearshift selector and crossover cable to shift levers at transaxle (Fig. 99). 8. Install and tighten the three grommet plate-to-floor pan nuts to 6 Nm (50 inch lbs.) torque. 9. Install selector cable to shifter lever and secure cable to shifter bracket. Install clip (Fig. 97). 10. Install crossover cable to shifter lever and secure cable to shifter bracket. Install clip (Fig. 96). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4386 NOTE: Only the crossover cable is adjustable. The selector cable does not have any adjustment capabilities. 11. Adjust crossover cable as follows: a. Loosen adjusting screw on crossover cable at shifter (Fig. 102). b. The gearshift mechanism and transaxle crossover lever are spring-loaded and self-centering. Alignment pins used in the past are not required anymore. Allow gearshift mechanism and transaxle crossover lever to relax in their neutral positions. To ensure the gearshift lever is in the proper position, place the shifter in 3rd or 4th gear if necessary. Torque adjustment screw to 8 Nm (70 inch lbs.). Care must be taken to avoid moving the shift mechanism off-center during screw tightening. c. Perform functional check by shifting transaxle into all gears. 12. Install center console assembly (Fig. 95). Verify that boot is not pinched at console opening before tightening. 13. Install knob/boot assembly to shifter lever, align knob to three o'clock position, push knob down to engage spring and rotate counter clockwise to secure (Fig. 94). 14. Locate boot to console at forward tab and secure with retaining tabs. 15. Return shifter boot to its original position (seated around knob lip). 16. Install the air cleaner/throttle body assy. (Fig. 98) as follows: a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assy. b. Install assy. into position, making sure the air cleaner locating slot is engaged to the battery bracket tab, and tighten fasteners to 14 Nm (120 inch lbs.) torque. c. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 Nm (40 inch lbs.) torque. d. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. e. Connect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body. 17. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair Shift Rail: Service and Repair T350 - Manual Transmission SHIFT RAIL BUSHINGS REMOVAL 1. Thread tool #6786 into shift rail bushing. 2. Install slide hammer #3752 onto tool. 3. Remove bushing using slide hammer and tool assembly (Fig. 144). INSTALLATION 1. Line up replacement bushing in bore. 2. Using tool #MD998343, tap bushing into bore until flush with the chamfer in the case. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Front Engine Mount to Trans ............................................................................................................... .................................................. 108 Nm (80 ft. lbs.) Front Mount Through Bolt ................................. ...................................................................................................................................... 61 Nm (45 ft. lbs.) Front Mount to Engine Bolt .......................................................................................................... ............................................................ 54 Nm (40 ft. lbs.) Left Mount Through Bolt ........................... ............................................................................................................................................ 108 Nm (80 ft. lbs.) Left Mount to Transaxle ..................................................................................................... ...................................................................... 54 Nm (40 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor ......................................................................................................................... ..................................................... 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4396 Transmission Speed Sensor: Description and Operation T350 - Manual Transmission DESCRIPTION - VEHICLE SPEED SENSOR 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4397 Transmission Speed Sensor: Service and Repair T350 - Manual Transmission VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector (Fig. 151). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt (Fig. 151). 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. Install pinion gear to speed sensor (Fig. 151). 2. Using a NEW O-ring, install the speed sensor to the transaxle (Fig. 151). 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector (Fig. 151). 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4408 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4409 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4410 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4416 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4417 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4418 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4419 Control Module: Locations Fig.11 TCM Location The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4420 Control Module: Description and Operation Fig.11 TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). It mounts on a bracket that is fastened to the rail. The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: -Battery (B+) voltage -Ignition "ON" voltage -Transmission Control Relay (Switched B+) -Throttle Position Sensor -Crankshaft Position Sensor (CKP) -Transmission Range Sensor (TRS) -Pressure Switches (L/R, 2/4, OD) -Transmission Temperature Sensor (Integral to TRS) -Input Shaft Speed Sensor -Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) - Torque Reduction Request (to PCM) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4421 An example of a TCM indirect output is: Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.12 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 12). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4422 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4423 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation Control Module: Service and Repair Removal and Installation REMOVAL NOTE: If the Transmission Control Module (TCM) is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE STANDARD PROCEDURE) 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Partially remove right front wheel splash shield. Fig.13 TCM 60-Way Connector 4. Disconnect TCM 60-way connector (Fig. 13). Fig.14 TCM/Bracket Assembly 5. Remove three (3) TCM bracket-to-rail screws and remove TCM/bracket assembly from vehicle (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 4426 Fig.15 TCM Bracket 6. Remove four (4) bracket-to-TCM screws and remove bracket (Fig. 15). INSTALLATION 1. Install TCM to mounting bracket and torque four (4) screws to 12 Nm (105 in. lbs.) (Fig. 15). 2. Install TCM/bracket assembly to rail (Fig. 14). Install and torque three (3) bracket-to-rail screws to 12 Nm (105 in. lbs.). 3. Install TCM 60-way connector and torque to 4 Nm (35 in. lbs.) (Fig. 13). 4. Install and secure right front wheel splash shield. 5. Lower vehicle. 6. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 4427 Control Module: Service and Repair Pinion Factor Setting STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRB III scan tool. 1. Plug the DRB III scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRB III scan tool screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Removal and Installation > Page 4428 Control Module: Service and Repair Quick Learn Procedure STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB III scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° 1. Plug the DRB III scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRB III to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4432 Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4433 Transmission Control System Relay: Diagrams Automatic Shut Down Relay Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4434 Transmission Control System Relay: Description and Operation 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 303) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications Solenoid/Pressure Switch Assembly-to-Case Bolt ................................................................................................................................ 12 Nm (110 in. lbs.) Solenoid/Pressure Switch Assembly Connector Screw ............................................................................................................................. 4 Nm (35 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4443 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4444 Fluid Pressure Sensor/Switch: Description and Operation 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 289) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4445 The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the chart shown. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate DTC will set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4446 Pressure Switch States Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4447 Fluid Pressure Sensor/Switch: Service and Repair 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 290). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 291). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4448 7. Remove solenoid/pressure switch assembly and gasket (Fig. 292). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 292). 2. Install and torque three (3) bolts (Fig. 291) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 290) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner/throttle body assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Interlock Mechanism Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4452 Shift Interlock Switch: Service and Repair REMOVAL Fig. 39 1. Remove the steering column lower cover (Fig. 39). Fig. 40 2. Remove the steering column upper and lower shrouds (Fig. 40). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4453 Fig. 41 3. Turn the ignition key to the "OFF" or "ON/ RUN" position (Fig. 41). Fig. 42 4. Grasp the interlock cable and connector firmly. Remove the interlock cable (Fig. 42). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4454 Fig. 43 5. Remove the two interlock mechanism-to-steering column attaching screws (Fig. 43). Remove the interlock housing. INSTALLATION 1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 Nm (21 inch lbs.). 2. Snap the interlock cable into the housing. 3. Install steering column upper and lower shrouds (Fig. 40). 4. Install steering column lower cover (Fig. 39). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations > Page 4458 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4462 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4463 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4464 Autostick Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 4470 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 4471 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4472 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4473 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4474 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4475 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4476 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4481 Transmission Speed Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4482 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4483 Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 293), sealed with an O-ring (Fig. 294), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4486 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 295), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4487 Transmission Speed Sensor: Description and Operation Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 298), sealed with an O-ring (Fig. 299), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4488 OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 300), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4489 Transmission Speed Sensor: Description and Operation Vehicle Speed Signal 41TE - Automatic Transmission VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 296). 5. Inspect speed sensor O-ring (Fig. 297) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Install air cleaner/throttle body assembly. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4492 Transmission Speed Sensor: Service and Repair Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 301). 5. Inspect speed sensor O-ring (Fig. 302) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 302). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor ......................................................................................................................... ..................................................... 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4497 Transmission Speed Sensor: Description and Operation T350 - Manual Transmission DESCRIPTION - VEHICLE SPEED SENSOR 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4498 Transmission Speed Sensor: Service and Repair T350 - Manual Transmission VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector (Fig. 151). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt (Fig. 151). 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. Install pinion gear to speed sensor (Fig. 151). 2. Using a NEW O-ring, install the speed sensor to the transaxle (Fig. 151). 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector (Fig. 151). 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4505 Shift Interlock Solenoid: Diagrams Brake Transmission Shift Interlock Solenoid Brake Transmission Shift Interlock Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4509 Shift Solenoid: Diagrams Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4510 8w-80-61 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4511 Solenoid Application Chart Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams Shift Indicator: Diagrams Trans Range Indicator Illumination (PRNDL)(Autostick) Trans Range Indicator Illumination (PRNDL) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Application and ID Transmission Mode Indicator - A/T: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Console Gear Selector w/ Auto ........................................................................................................... .............................................................. PC 194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: Customer Interest A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4530 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4531 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4532 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts Control Module: All Technical Service Bulletins A/T - Harsh 4th to 3rd Gear Downshifts NUMBER: 21-006-03 REV. A GROUP: Transmission DATE: August 1, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-006-03, DATE JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITION OF KJ AND 2.4L RS VEHICLES, REVISED NOTES, AND NEW APPLICATION TABLE. **THE SOFTWARE IS CURRENTLY AVAILABLE ON TechCONNECT FOR CS, JR, LH, PL, PT, 3.3L AND 3.8L RS/RG, AND TJ VEHICLES**. **THIS BULLETIN IS BEING PROVIDED IN ADVANCE FOR 2.4L RS/RG VEHICLES. THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER AUGUST 18, 2003. KJ SOFTWARE WILL BE AVAILABLE ON TechCONNECT ON OR AFTER SEPTEMBER 3, 2003.** SUBJECT: Transmission Harsh 4-3 Downshift OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2004 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2003 (KJ) Liberty** **2003 (KJ) Cherokee (International Markets)** 2003 - 2004 (LH) 300M/Concorde/Intrepid 2003 (PL) Neon/SX 2.0 2003 (PT) PT Cruiser 2003 (RG) Chrysler Voyager (International Markets) 2003 (RS) Town & Country/Caravan/Voyager 2003 (TJ) Wrangler Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4538 NOTE: **Refer to the following table for specific applications. ** SYMPTOM/CONDITION: Vehicle may exhibit, after an extended soak (several hours), a harsh 4-3 downshift. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: **An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed.** REPAIR PROCEDURE: 1. Check the transmission fluid level. If fluid level is full proceed to step 2. If fluid level is low, diagnose and repair fluid leak. Proceed to step 2. NOTE: Whenever a PCM/TCM is replaced or reprogrammed, the software in the controller and DRBIII(R) must be verified as having the latest revision level. If a controller software update flash is available, complete the flash and labeling requirement as directed in the appropriate service bulletin identified on the TechCONNECT. 2. Connect a battery charger and set as close to 14 volts charge as possible. 3. Flash the controller using the TechCONNECT and DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4539 NOTE: **Using the DRBIII(R) preform the proper Quick Learn procedure. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E - Electronic Control Modules.** NOTE: Due to the PCM reprogramming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. All DTC's relate to a loss of communications with the module that is being reprogrammed. Check all modules, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following steps are required by law. 4. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the controller and cover the label with the clear plastic overlay. 5. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-006-03A > Aug > 03 > A/T - Harsh 4th to 3rd Gear Downshifts > Page 4540 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 4541 Control Module: Locations Fig.11 TCM Location The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 4542 Control Module: Description and Operation Fig.11 TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) is located behind the passenger fender and is fastened to the frame rail forward of the suspension (Fig. 11). It mounts on a bracket that is fastened to the rail. The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: -Battery (B+) voltage -Ignition "ON" voltage -Transmission Control Relay (Switched B+) -Throttle Position Sensor -Crankshaft Position Sensor (CKP) -Transmission Range Sensor (TRS) -Pressure Switches (L/R, 2/4, OD) -Transmission Temperature Sensor (Integral to TRS) -Input Shaft Speed Sensor -Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) - Torque Reduction Request (to PCM) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 4543 An example of a TCM indirect output is: Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.12 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 12). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 4544 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Technical Service Bulletins > Page 4545 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation Control Module: Service and Repair Removal and Installation REMOVAL NOTE: If the Transmission Control Module (TCM) is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE STANDARD PROCEDURE) 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Partially remove right front wheel splash shield. Fig.13 TCM 60-Way Connector 4. Disconnect TCM 60-way connector (Fig. 13). Fig.14 TCM/Bracket Assembly 5. Remove three (3) TCM bracket-to-rail screws and remove TCM/bracket assembly from vehicle (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation > Page 4548 Fig.15 TCM Bracket 6. Remove four (4) bracket-to-TCM screws and remove bracket (Fig. 15). INSTALLATION 1. Install TCM to mounting bracket and torque four (4) screws to 12 Nm (105 in. lbs.) (Fig. 15). 2. Install TCM/bracket assembly to rail (Fig. 14). Install and torque three (3) bracket-to-rail screws to 12 Nm (105 in. lbs.). 3. Install TCM 60-way connector and torque to 4 Nm (35 in. lbs.) (Fig. 13). 4. Install and secure right front wheel splash shield. 5. Lower vehicle. 6. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation > Page 4549 Control Module: Service and Repair Pinion Factor Setting STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a DRB III scan tool. 1. Plug the DRB III scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the DRB III scan tool screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Service and Repair > Removal and Installation > Page 4550 Control Module: Service and Repair Quick Learn Procedure STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB III scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Transmission Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° 1. Plug the DRB III scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the DRB III to perform the Quick Learn Procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4554 Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4555 Transmission Control System Relay: Diagrams Automatic Shut Down Relay Transmission Control Relay (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4556 Transmission Control System Relay: Description and Operation 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 303) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications Solenoid/Pressure Switch Assembly-to-Case Bolt ................................................................................................................................ 12 Nm (110 in. lbs.) Solenoid/Pressure Switch Assembly Connector Screw ............................................................................................................................. 4 Nm (35 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4565 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4566 Fluid Pressure Sensor/Switch: Description and Operation 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 289) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4567 The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the chart shown. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate DTC will set. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4568 Pressure Switch States Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4569 Fluid Pressure Sensor/Switch: Service and Repair 41TE - Automatic Transmission SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 290). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 291). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 4570 7. Remove solenoid/pressure switch assembly and gasket (Fig. 292). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 292). 2. Install and torque three (3) bolts (Fig. 291) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 290) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner/throttle body assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Shift Interlock Switch: Locations Interlock Mechanism Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4574 Shift Interlock Switch: Service and Repair REMOVAL Fig. 39 1. Remove the steering column lower cover (Fig. 39). Fig. 40 2. Remove the steering column upper and lower shrouds (Fig. 40). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4575 Fig. 41 3. Turn the ignition key to the "OFF" or "ON/ RUN" position (Fig. 41). Fig. 42 4. Grasp the interlock cable and connector firmly. Remove the interlock cable (Fig. 42). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4576 Fig. 43 5. Remove the two interlock mechanism-to-steering column attaching screws (Fig. 43). Remove the interlock housing. INSTALLATION 1. Position the interlock housing at steering column. Install the two interlock mechanism-to-steering column attaching screws. Torque screws to 3 Nm (21 inch lbs.). 2. Snap the interlock cable into the housing. 3. Install steering column upper and lower shrouds (Fig. 40). 4. Install steering column lower cover (Fig. 39). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Locations > Page 4580 Transmission Solenoid/Pressure Switch Assembly (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Transmission Mode Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4584 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4585 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4586 Autostick Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Transmission Range Sensor ............................................................................................................... ........................................................ 5 Nm (45 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 4592 Transmission Position Switch/Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Component Locations > Page 4593 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4594 Transmission Range Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4595 Transmission Position Switch/Sensor: Description and Operation 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 304). The TRS has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 305). OPERATION The Transmission Range Sensor (TRS) (Fig. 304) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4596 TRANSMISSION RANGE SENSOR SWITCH STATES Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 305) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4597 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 > Locations > Page 4598 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 304). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 304) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4603 Transmission Speed Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4604 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4605 Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 293), sealed with an O-ring (Fig. 294), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4608 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 295), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4609 Transmission Speed Sensor: Description and Operation Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 298), sealed with an O-ring (Fig. 299), and is considered a primary input to the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4610 OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 300), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 4611 Transmission Speed Sensor: Description and Operation Vehicle Speed Signal 41TE - Automatic Transmission VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - INPUT REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner/throttle body assembly. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 296). 5. Inspect speed sensor O-ring (Fig. 297) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Install air cleaner/throttle body assembly. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4614 Transmission Speed Sensor: Service and Repair Output Speed Sensor 41TE - Automatic Transmission SPEED SENSOR - OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 301). 5. Inspect speed sensor O-ring (Fig. 302) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 302). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor ......................................................................................................................... ..................................................... 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4619 Transmission Speed Sensor: Description and Operation T350 - Manual Transmission DESCRIPTION - VEHICLE SPEED SENSOR 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4620 Transmission Speed Sensor: Service and Repair T350 - Manual Transmission VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector (Fig. 151). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt (Fig. 151). 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. Install pinion gear to speed sensor (Fig. 151). 2. Using a NEW O-ring, install the speed sensor to the transaxle (Fig. 151). 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector (Fig. 151). 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations ABS Light: Locations The amber ABS warning indicator lamp is located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4626 ABS Light: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application ABS Indicator ....................................................................................................................................... ................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4627 ABS Light: Description and Operation ABS WARNING INDICATOR The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off due to a system malfunction. The CAB controls the lamp indirectly. The CAB monitors its own functions. If the CAB determines that the ABS warning indicator should be on, the CAB sends a message via the PCI BUS to the instrument cluster and the cluster turns on the indicator. The indicator will remain lit during every key cycle until the circuit or component fault is repaired and the CAB no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TRAC OFF Indicators. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB. When the ignition key is turned to the ON position, the amber ABS warning indicator lamp is lit until the Controller Antilock Brake (CAB) completes its self-tests and turns OFF the lamp (approximately 4 seconds). The amber ABS warning indicator lamp will illuminate when the CAB detects a condition that results in the shutdown of ABS function. The CAB sends a message to the Mechanical Instrument Cluster (MIC) instructing it to turn ON the amber ABS warning indicator lamp. Under most conditions, when the amber ABS warning indicator lamp is ON, only the ABS function of the brake system is affected; The Electronic Brake Distribution (EBD), the base brake system and the ability to stop the vehicle are not affected. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Fig.1 Integrated Control Unit (ICU) The CAB is mounted to the ICU as part of the Integrated Control Unit (ICU). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4634 Controller Antilock Brake Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4635 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. Fig.3 CAB Mounting 3. Disconnect pump/motor connector from CAB. 4. Remove four screws securing CAB to HCU half of ICU. Remove CAB from HCU. 5. Pull outward on CAB connector lock and disconnect 24-way wiring connector. Remove CAB from vehicle. INSTALLATION 1. Connect 24-way wiring connector to CAB and push in connector lock. 2. Align CAB with HCU half of ICU, then slide CAB up over HCU valves. Install four CAB mounting screws. Tighten mounting screws to 2 Nm (17 in. lbs.) torque. 3. Connect pump/motor connector. 4. Lower vehicle. 5. Connect battery negative cable. 6. Connect DRBIII to vehicle to initialize system. Check and clear any faults. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS HYDRAULIC CONTROL UNIT Hydraulic Tube Fitting Type ........................................................................................................................................................ SAE 45° Inverted Flare Inlet Port Threads .......................................................................................... ........................................................................................................ 7/16-24 Outlet Port Threads Left Front and Left Rear ...................................................................................................................................................... 7/16-24 Outlet Port Threads - Right Front and Right Rear ................................................................................................................................................... 3/8-24 BRAKE FASTENER TORQUE ABS ICU Mounting Bolts (To Bracket) .............................................................................................................................................. 11 Nm (97 in. lbs.) ABS ICU Mounting Bolts (To Frame) ............................................................................................................................................... 23 Nm (200 in. lbs.) ABS CAB Mounting Screws (To HCU) ............................................................................................................................................. 2 Nm (17 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4639 Hydraulic Control Assembly - Antilock Brakes: Locations Hydraulic Control Unit Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU) The Hydraulic Control Unit (HCU) is mounted to the CAB as part of the ICU. The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are spring loaded in the open position and the outlet valves are spring-loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/ motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. There are two noise dampening chambers in the HCU on this vehicle equipped with traction control. PUMP/MOTOR There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the CAB. The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, these pistons are used to purge fluid from the accumulators back into the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The pump motor is also used to build pressure when the system goes into traction control mode. The CAB may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. OPERATION - HYDRAULIC CIRCUITS AND VALVES The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4642 following paragraphs explain how this works. For purposes of explanation only, it is assumed that only the right front wheel is experiencing antilock braking; the following diagrams show only the right front wheel in an antilock braking operation. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram shows the vehicle in the normal braking mode of the base brake hydraulic system. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal; this builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4643 The hydraulic diagram shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4644 Hydraulic Control Assembly - Antilock Brakes: Description and Operation ICU (Integrated Control Unit) ICU (INTEGRATED CONTROL UNIT) DESCRIPTION The Hydraulic Control Unit (HCU) and the Controller Antilock Brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU is located on the driver's side of the vehicle, below the master cylinder. The ABS with traction control ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two hydraulic shuttle valves, two traction control valves, valve block, fluid accumulators, a pump, and an electric pump/motor. The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any components of the HCU or CAB. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4645 Hydraulic Control Assembly - Antilock Brakes: Service and Repair INTEGRATED CONTROL UNIT (ICU) NOTE: If servicing the Controller Antilock Brake (CAB) only, the CAB can be serviced with the ICU mounted in the vehicle. REMOVAL- ICU NOTE: Before proceeding, Refer to Service Precautions. Brake Pedal Holding Tool Installed 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Disconnect negative (ground) cable from the battery and isolate the cable. 3. Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place. 4. Remove the one nut and one bolt securing the air cleaner box in place, then disconnect the wiring harness connector at the air inlet sensor. 5. Lift the air cleaner box upward enough to clear its grommeted alignment post, then move the air cleaner box forward just enough to access the battery tray mounting bolts. 6. Remove the 2 bolts, then the 2 nuts mounting the battery tray to its bracket. Remove the battery tray. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4646 7. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs in the master cylinder outlet ports. 8. Disconnect the 24-way connector from the Controller Antilock Brake (CAB) mounted on the Integrated Control Unit (ICU) and move it out of the way. The connector is disconnected by pulling outward on the connector lock. This will unlock and raise the 24-way connector out of the socket on the CAB. 9. Tag the brake tubes coming from the master cylinder as primary and secondary. This is done to avoid mix-up once the tubes are removed from the vehicle. 10. Disconnect and remove the primary and secondary brake tubes coming from the master cylinder at the ICU Hydraulic Control Unit (HCU). 11. Disconnect the brake tubes going to each individual brake at the HCU. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4647 12. Remove the 3 bolts attaching the ICU to its mounting bracket. 13. Remove the ICU from the vehicle. 14. If the CAB and HCU must be separated, Refer to ICU (INTEGRATED CONTROL UNIT) - DISASSEMBLY. DISASSEMBLY- ICU NOTE: To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this vehicle, the entire Integrated Control Unit (ICU) needs to be removed from the vehicle. The CAB can then be separated from the HCU. 1. Disconnect the pump/motor wiring harness from the CAB. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4648 2. Remove the 4 bolts attaching the CAB to the HCU3). 3. Remove the CAB from the HCU. ASSEMBLY- ICU Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4649 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU). Tighten the CAB mounting bolts to a torque of 2 Nm (17 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4650 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle. INSTALLATION- ICU 1. Install the ICU onto its mounting bracket. 2. Install the 3 bolts attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 in. lbs.) Brake Pedal Holding Tool Installed 3. Install the four brake tubes going to the brakes into their respective outlet ports on the ICU HCU. Using a crow foot on a torque wrench, tighten the four brake tube nuts to a torque of 17 Nm (145 in. lbs.). NOTE: When installing the brake tubes from the master cylinder on the HCU, the brake tube with the small tube nut is to be installed in the forward-most port on the HCU with the small end going toward the master cylinder secondary port. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4651 4. Install the primary and secondary brake tubes from the master cylinder onto the HCU. Do not completely tighten the primary and secondary tubes at this time. 5. Connect the primary and secondary brake tubes to the master cylinder ports. 6. Using a crow foot on a torque wrench, tighten the primary and secondary brake tube nuts at both the master cylinder and HCU to a torque of 17 Nm (145 in. lbs.). CAUTION: Before installing the 24-way connector in the CAB, be sure the seal is properly installed in the connector. 7. Install the 24-way connector into the socket of the CAB as follows: - Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible. - When the connector is fully seated into the CAB socket, push the connector lock inward. This pulls the connector into the socket of the CAB and locks it in the installed position. 8. Position the battery tray back in place. Install the two bolts, then the two nuts mounting the battery tray to its bracket. Tighten the two bolts and nuts to a torque of 15 Nm (135 in. lbs.). 9. Reinstall the air cleaner box onto its grommeted alignment post. 10. Install the one nut and one bolt securing the air cleaner box in place, then connect the wiring harness connector at the air inlet sensor. 11. Install the battery and clamp it in place. Tighten the hold-down clamp bolt to a torque of 12 Nm (105 in. lbs.). 12. Connect the positive, then the negative (ground) cable on the battery. NOTE: The ICU may need to be initialized using the DRBIII scan tool after ICU installation. Refer to Appropriate Diagnostic Information. 13. Bleed the base brakes and ABS hydraulic systems. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 4652 14. Fill the master cylinder to the proper fill level. 15. Road test the vehicle to ensure proper operation of the base and antilock brake systems. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Application and ID Traction Control Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Trac OFF Indicator .............................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications TORQUE SPECIFICATIONS ABS Wheel Speed Sensor Mounting Screw ...................................................................................................................................... 12 Nm (105 in. lbs.) WHEEL SPEED SENSOR AIR GAP Front Sensor ........................................................................................................................................ ......................... 0.28 - 1.42 mm (0.011 - 0.056 in.) Rear Sensor ........................................................ .......................................................................................................... 0.45 - 1.12 mm (0.018 - 0.044 in.) TONE WHEEL RUNOUT Front .................................................................................................................................................... ................................................................. 0.009 in. Rear .................................................................... .................................................................................................................................................. 0.009 in. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations TONE WHEELS FRONT REAR WHEEL SPEED SENSORS FRONT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4661 REAR Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4662 Wheel Speed Sensor: Connector Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4663 Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4664 Fig. 5 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4665 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4666 Fig. 37 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4667 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4668 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4669 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4670 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Right Rear Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel Wheel Speed Sensor: Description and Operation Tone Wheel TONE WHEEL DESCRIPTION The tone wheel is used in conjunction with the wheel speed sensors. OPERATION The tone wheel is used in conjunction with the wheel speed sensors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4673 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor Front FRONT WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A wheel speed sensor is used at each wheel. The gear (tooth) type tone wheel serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one tone wheel. The front wheel speed sensors are attached to bosses in the steering knuckle. The tone wheel is an integral part of the outboard constant velocity joint located in the front axle shaft. WSS air gaps are not adjustable. The initial factory WSS air gap specification can be found in SPECIFICATIONS. Each WSS is serviced individually. The tone wheels are serviced as Dart of the drive shaft. OPERATION The CAB sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the CAB. The Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4674 relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the CAB, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the CAB. When a valley of the tone wheel is aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the CAB. As the tone wheel rotates, the tooth shifts the magnetic field and the IC enables a second 7 mA current source. The CAB senses a voltage signal of approximately 1.6 volts and 14 mA. The CAB measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABS CAB as the wheel speed. Rear REAR WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A wheel speed sensor is used at each wheel. The gear (tooth) type tone wheel serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one tone wheel. The rear wheel speed sensors are mounted through the disc brake adapter. The rear tone wheels are mounted to and rotate with the hub and bearing assemblies. The WSS air gaps are not adjustable. The initial factory WSS air gap specification can be found in SPECIFICATIONS. Each WSS is serviced Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4675 individually. The tone wheels are serviced as an assembly with the hub and bearing assemblies. OPERATION The CAB sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the CAB. The relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the CAB, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the CAB. When a valley of the tone wheel is aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the CAB. As the tone wheel rotates, the tooth shifts the magnetic field and the IC enables a second 7 mA current source. The CAB senses a voltage signal of approximately 1.6 volts and 14 mA. The CAB measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABS CAB as the wheel speed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Page 4676 Wheel Speed Sensor: Testing and Inspection TONE WHEEL INSPECTION Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes: missing, chipped, or broken teeth - contact with the wheel speed sensor - wheel speed sensor to tone wheel alignment - wheel speed sensor to tone wheel clearance - excessive tone wheel runout - tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement, the rear hub and bearing must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive tone wheel runout can cause erratic wheel speed sensor signals. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replace the front driveshaft or rear hub and bearing as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Raise the vehicle. 2. Disconnect the wheel speed sensor cable connector from the wiring harness on the inside of the frame rail above the front suspension crossmember. The connector has a locking tab which that must be pulled back before the connector release tang can be depressed, releasing the connection. 3. If the sensor being removed is a left front, unclip the speed sensor cable from the brake tube on the inside of and under the frame rail. 4. Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4679 5. Remove the bolt mounting the wheel speed sensor head to the steering knuckle. CAUTION: When removing a wheel speed sensor from the knuckle, do not use pliers on the sensor head. This may damage the sensor head. If the sensor has seized, use a hammer and a punch to tap the edge of the sensor head ear, rocking the sensor side-to-side until free. 6. Carefully, remove the sensor head from the steering knuckle. 7. Remove the screw securing the wheel speed sensor to the rear of the strut. Remove the wheel speed sensor. INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Attach the wheel speed sensor to the strut using the its mounting screw. 2. Install the wheel speed sensor head in the steering knuckle. Install the mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. From the sensor bracket on the strut, loop the sensor cable upward, then downward at the outside of the frame rail. Install the speed sensor cable grommet onto the retaining bracket attached to the brake hose on the outside of the frame rail. 4. Loop the wheel speed sensor cable around the bottom of the frame rail and connect it to the wiring harness connector on the inside of the frame rail. Remember to push in the locking tab on the connector. 5. If the sensor being installed is the left front, clip the speed sensor cable to the brake tube on the inside of and under the frame rail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4680 6. Lower the vehicle. 7. Road test vehicle to ensure proper operation of the base brakes and ABS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4681 Wheel Speed Sensor: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Raise the vehicle. 2. Disconnect the wheel speed sensor cable connector from the vehicle wiring harness. Remove the clip attaching wheel speed sensor cable connector to the vehicle's body. 3. Remove the wheel 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. 4. Remove the bolt attaching the wheel speed sensor cable routing bracket to rear strut. CAUTION: When removing a wheel speed sensor from the rear disc brake adapter, do not use pliers on the sensor head. This may damage the sensor head. If the sensor has seized, use a hammer and a punch to tap the edge of the sensor head ear, rocking the sensor side-to-side until free. 5. Remove the bolt attaching the wheel speed sensor to the rear disc brake adapter, then carefully remove the sensor head from the rear disc brake Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4682 adapter and vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head into the disc brake adapter. 2. Install the wheel speed sensor mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. Install the wheel speed sensor cable routing bracket on the rear strut. 4. Install wheel speed sensor cable into the routing clips on the rear brake hose and brake tube. 5. Connect the wheel speed sensor cable connector into vehicle wiring harness. Install the clip attaching the wheel speed sensor cable connector to vehicle's body. 6. Lower the vehicle. 7. Road test the vehicle to ensure proper operation of the base brakes and ABS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise. 2. Refer to one of the following depending on whether the master cylinder is a non-ABS unit Step a or an ABS unit Step b: a. Attach four Master Cylinder Bleed Tubes, Special Tool 8358-1, to the four ports of the master cylinder and tighten each in place. The bleed tubes for the ports pertaining to the rear brakes are made to attach to the proportioning valves screwed into the master cylinder. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. b. Attach Master Cylinder Bleed Tube, Special Tool 8358-1, to the primary port of the master cylinder and tighten in place. Attach Master Cylinder Bleed Tube, Special Tool 8358-2, to the secondary port of the master cylinder and tighten in place. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. 3. Fill the brake fluid reservoir with fresh Mopars brake fluid, or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel as a pushrod, press the pistons inward slowly applying brake pressure, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled out of the tubes and master cylinder bore. 5. Remove the bleed tubes from the master cylinder and plug the outlet ports. 6. Install the fill cap on the reservoir. 7. Remove the master cylinder from the vise. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4687 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. - Use only Mopar brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not pump the brake pedal at any time while a bleeder screw is open. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4688 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRBIII scan tool to the Data Link Connector. The connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRBIII, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRBIII. 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 YOURSELF AND 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. 5. Using the DRBIII, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4689 Brake Bleeding: Service and Repair Standard Procedure - Manual Bleeding MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least 1 full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4690 Brake Bleeding: Service and Repair Standard Procedure - Pressure Bleeding PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Following the same wheel circuit sequence as prescribed for manual bleeding. 1. Attach Adapter, Special Tool 6921, to the master cylinder reservoir. 2. Attach Bleeder Tank, Special Tool C-3496-B, or an equivalent, to the adapter on the master cylinder. 3. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 4-8 ounces of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal Ratio 3.41 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle Brake Pedal Assy: Service and Repair With Automatic Transaxle PEDAL REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. WITH AUTOMATIC TRANSAXLE 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Place the steering wheel and tires in the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation. 3. Remove the steering column coupling retainer pin, back off the pinch bolt nut, and remove the steering column coupling pinch bolt (the pinch bolt nut is caged to the coupling and is not removable). Separate the upper and lower steering column couplings. 4. Remove the brake lamp switch. 5. Remove the clip securing the power brake booster input rod to the brake pedal. Remove the input rod from the brake pedal. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle > Page 4696 6. Remove the two upper nuts fastening the brake pedal bracket to the power brake booster. 7. Carefully pry the tie bar running between the two upper booster mounting studs from its plastic retaining fasteners. 8. Remove the two remaining nuts fastening the brake pedal bracket to the power brake booster. 9. If the vehicle is equipped with antilock brakes, carefully push the power brake booster forward until the booster contacts the ABS ICU mounting bracket. 10. If the vehicle does not have antilock brakes, carefully push the power brake booster forward one to two inches being careful not to stretch the brake lines from the master cylinder to the brakes. 11. Remove the two nuts fastening the brake pedal bracket to the instrument panel support. 12. Carefully remove the brake pedal assembly by pulling the pedal bracket back toward the instrument panel, releasing the bracket from the booster studs. Next, tip the bracket down past the input rod, guiding the rod through the gap left by the missing brace removed in Step (8). Remove the brake pedal assembly out from under the instrument panel. 13. The pedal can be removed from it's bracket by grinding off the peened end of the shaft, removing the shaft, pedal and bushings. A service parts package is available to replace these items. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. WITH AUTOMATIC TRANSAXLE 1. If the pedal has been removed from it's bracket, install the pedal, bushings and bolt-in-shaft on the bracket using the available service parts package. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle > Page 4697 2. Install the brake pedal assembly by tipping the pedal bracket and guiding the power brake booster mounting portion up past the booster input rod. Guide the top of the bracket onto the studs protruding from the instrument panel support, then guide the booster mounting portion onto the power brake booster mounting studs. 3. Push the power brake booster back into mounting position from under the hood. 4. Install the two nuts fastening the brake pedal bracket to the instrument panel support. Install the nuts all the way, but do not tighten them at this time. 5. Install the two lower power brake booster mounting nuts, but do not tighten them at this time. 6. Place the tie bar running between the two upper booster mounting studs onto the studs with the long flat side facing upward and the curved side downward. 7. Install the two upper power brake booster mounting nuts on their studs. 8. Tighten all four nuts fastening the brake pedal bracket to the power brake booster to a torque of 34 Nm (300 in. lbs.). 9. Tighten the two nuts fastening the brake pedal bracket to the instrument panel support to a torque of 34 Nm (300 in. lbs.). 10. Install the power brake booster input rod on the pin mounted on the side of the brake pedal. Install a new retaining clip on the end of the pin. Do not reuse the old clip. 11. Mount a new brake lamp switch into the bracket. 12. Install the dash-to-lower coupling seal in place over the lower coupling's plastic collar and dash cover. 13. Verify the front tires are still in the STRAIGHT-AHEAD position. 14. Reconnect the steering column lower coupling to the steering column upper coupling. Install the coupling pinch bolt an tighten the pinch bolt nut to a torque of 28 Nm (250 in. lbs.). Install the pinch bolt retainer pin. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle > Page 4698 15. Remove the steering wheel holder. 16. While looking under the instrument panel at the lower coupling, rotate the steering wheel back and-forth to verify that the lower coupling does not squeak against the dash-to-coupling seal. 17. Reconnect the battery negative terminal. 18. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 19. Road test the vehicle to ensure proper operation of the brakes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle > Page 4699 Brake Pedal Assy: Service and Repair With Manual Transaxle PEDAL REMOVAL WITH MANUAL TRANSAXLE 1. Remove the instrument panel. 2. Remove the brake lamp switch. 3. Disconnect the clutch cable from the clutch pedal spacer. 4. Disconnect the wiring harness connector going to the clutch pedal switches. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle > Page 4700 5. Remove the clip securing the power brake booster input rod to the brake pedal. Remove the input rod from the brake pedal. 6. Remove the four nuts fastening the brake pedal bracket to the power brake booster. 7. Remove the two nuts fastening the brake pedal bracket to the instrument panel support. 8. Remove the brake pedal assembly. 9. The pedal can be removed from it's bracket by grinding off the peened end of the shaft, removing the shaft, pedal and bushings. A service parts package is available to replace these items. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. WITH MANUAL TRANSAXLE 1. If the pedal has been removed from it's bracket, install the pedal, bushings and bolt-in-shaft on the bracket using the available service parts package. 2. Install the brake pedal assembly onto the studs extending down from the instrument panel support and power brake booster. 3. Install the two nuts fastening the brake pedal bracket to the instrument panel support. Install the nuts all the way, but do not tighten them at this time. 4. Install the power brake booster mounting nuts. Tighten the four nuts fastening the brake pedal bracket to the power brake booster to a torque of 34 Nm (300 in. lbs.). 5. Tighten the two nuts fastening the brake pedal bracket to the instrument panel support to a torque of 34 Nm (300 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transaxle > Page 4701 6. Connect the clutch cable to the clutch pedal spacer on the pedal. 7. Connect the wiring harness connector going to the clutch pedal switches. 8. Install the power brake booster input rod on the pin mounted on the side of the brake pedal. Install a new retaining clip on the end of the pin. Do not reuse the old clip. 9. Mount a new brake lamp switch into the bracket. 10. Install the instrument panel. 11. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 12. Road test the vehicle to ensure proper operation of the brakes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Brake System Warning Indicator ......................................................................................................... .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions > Page 4705 Brake Warning Indicator: Testing and Inspection BRAKE/PARK BRAKE INDICATOR 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 To test the service brake warning system, refer to Brakes, Hydraulic System Control Valves. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Banjo Bolt ............................................................................................................. .................................................... 47 Nm (35 ft. lbs.) Disc Brake Caliper Adapter (To Knuckle) Rear .................................................................................................................................... 75 Nm (55 ft. lbs.) Disc Brake Caliper Guide Pin Bolts ...................................................................................................................................................... 22 Nm (192 in. lbs.) Disc Brake Caliper Bleeder Screw ......................................................................................................................................................... 15 Nm (125 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper Brake Caliper: Service and Repair Front Disc Brake Caliper REMOVAL- DISC BRAKE CALIPER (FRONT) NOTE: Before proceeding, Refer to Service Precautions. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise the vehicle. 3. Remove the front tire and wheel assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard these washers. Replace them with new ones. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4712 5. Remove the two brake caliper to steering knuckle guide pin bolts. 6. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side caliper) or bottom (left side caliper) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide abutment (on the knuckle) and brake rotor. DISASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. Removing Inner Sleeve From Bushing 1. With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4713 2. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. DISASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) Before disassembling the brake caliper, clean and inspect it. CALIPER PISTON REMOVAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CALIPER SEAL REMOVAL CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. To disassemble the caliper, mount it in a vise equipped with protective jaws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4714 2. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 3. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore. Discard the old seal. 4. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4715 5. 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 the equivalent to hone the bore. Do not overhone the bore. Don not increase the diameter of the bore more than 0.0254 mm (0.001 inch). If the bore does not clean up within this specification, a new caliper housing should be installed. NOTE: During the honing procedure, 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 bore with fresh clean brake fluid; wipe it dry with a clean, lint free cloth and then clean it a second time. 6. Inspect the caliper piston for pitting, scratches, or any physical damage. Replace the piston if there is evidence of scratches, pitting or physical damage. CLEANING - DISC BRAKE CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopars Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - DISC BRAKE CALIPER Inspect the disc brake caliper for the following: Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4716 Folded Caliper Guide Pin Bushing 1. Fold the guide pin bushing in half lengthwise at the solid middle section. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4717 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. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar Dielectric Grease or an equivalent. 5. Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve. 6. Holding the convoluted boot on the opposite end of the bushing, push the steel sleeve through the bushing until the bushing boot is fully seated into the seal groove on that end of sleeve . Install the other end bushing boot into the groove on that end of the bushing sleeve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4718 7. Verify both ends of the bushing are seated in the sleeve groves. When the sleeve is seated properly into the bushing, the sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. ASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) NOTE: Never use an old piston seal. Installing New Piston Seal In Caliper 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4719 Installing Piston Into Caliper Bore 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689, and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper. 7. Install the brake shoes. 8. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION - DISC BRAKE CALIPER (FRONT) 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 caliper slide abutments with a liberal amount of Mopars Multipurpose Lubricant, or an equivalent. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4720 3. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top caliper slide abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower caliper slide abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 4. Install the caliper guide pin bolts and tighten them to a torque of 22 Nm (192 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4721 5. Install the banjo bolt connecting the brake hose to the brake caliper. Install NEW washers with the banjo bolt. Place one NEW washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to a torque of 48 Nm (35 ft. lbs.). 6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Remove the brake pedal holding tool. 9. Bleed the caliper as necessary. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4722 Brake Caliper: Service and Repair Rear Disc Brake Caliper REMOVAL- DISC BRAKE CALIPER (REAR) 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 2. Raise the vehicle. 3. Remove the rear tire and wheel assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard these washers. Replace them with new ones. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4723 5. Remove the two caliper guide pin bolts. Caliper Removal/Installation 6. Remove the caliper assembly from the brake adapter by first rotating the top of the caliper away from the rotor, and then lifting the caliper assembly off the machined abutment on the adapter. DISASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4724 1. With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing. 2. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. DISASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) Before disassembling the brake caliper, clean and inspect it. CALIPER PISTON REMOVAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4725 NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CALIPER SEAL REMOVAL CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. To disassemble the caliper, mount it in a vise equipped with protective jaws. Fig. 10 Dust Boot Removal 2. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4726 Removing Piston Seal From Caliper 3. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore. Discard the old seal. 4. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 5. 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 the equivalent to hone the bore. Do not over-hone the bore. Don not increase the diameter of the bore more than 0.0254 mm (0.001 inch). If the bore does not clean up within this specification, a new caliper housing should be installed. NOTE: During the honing procedure, 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 bore with fresh clean brake fluid; wipe it dry with a clean, lint free cloth and then clean it a second time. 6. Inspect the caliper piston for pitting, scratches, or any physical damage. Replace the piston if there is evidence of scratches, pitting or physical damage. CLEANING - DISC BRAKE CALIPER Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4727 WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopars Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - DISC BRAKE CALIPER Inspect the disc brake caliper for the following: Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Folded Caliper Guide Pin Bushing 1. Fold the guide pin bushing in half lengthwise at the solid middle section. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4728 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper mounting boss using your fingers . 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar Dielectric Grease or an equivalent. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4729 Fig 7 Installing Caliper Sleeves 5. Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve. 6. Holding the convoluted boot on the opposite end of the bushing, push the steel sleeve through the bushing until the bushing boot is fully seated into the seal groove on that end of sleeve. Install the other end bushing boot into the groove on that end of the bushing sleeve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4730 Fig 8 Installed Caliper Bushing Sleeve 7. Verify both ends of the bushing are seated in the sleeve groves. When the sleeve is seated properly into the bushing, the sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. ASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) NOTE: Never use an old piston seal. 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. Installing New Piston Seal In Caliper 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4731 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. Installing Piston Into Caliper Bore 6. Using a hammer and Installer, Special Tool C-4689, and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper. 7. Install the brake shoes. 8. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION - DISC BRAKE CALIPER (REAR) NOTE: Step (1) below is only required when installing the disc brake caliper after new brake shoes have been installed. 1. Completely retract the caliper piston back into piston bore of the caliper. 2. Lubricate both adapter caliper slide abutments with a liberal amount of Mopars Multipurpose Lubricant, or an equivalent. CAUTION: Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4732 Caliper Removal/Installation 3. Starting with the lower end, carefully lower the caliper and brake shoes over the brake rotor and catch the caliper's bottom edge behind the caliper slide abutment. Rotate the top of the caliper into mounting position on the adapter. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. 4. Carefully install the caliper guide pin bolts, then tighten them to a torque of 22 Nm (192 in. lbs.). 5. Install the banjo bolt connecting the brake hose to the brake caliper . Install NEW washers with the banjo bolt. Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to a torque of 48 Nm (35 ft. lbs.). 6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Remove the brake pedal holding tool. 9. Bleed the caliper as necessary. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications BRAKE PAD/SHOE THICKNESS SPECIFICATIONS Front Brakes 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. Rear Brakes 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 (L4-2.0L VIN F HO (2003)) 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- DISC BRAKE SHOES (FRONT) NOTE: Before proceeding with this procedure, Refer to Service Precautions. - Some vehicles use a different lining material on the front disc brake shoes than other vehicles. When new brake shoes are installed, be sure the brake shoes for the correct type of brake system are used. 1. Raise the vehicle. 2. Remove both front tire and wheel assemblies from vehicle. 3. Begin on one side of the vehicle. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. 4. Remove the two brake caliper guide pin bolts. 5. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side caliper) or bottom (left side caliper) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide abutment (on the knuckle) and brake rotor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4738 6. Support the caliper using a wire or cord to prevent the weight of caliper from damaging the brake hose. Do not let the caliper hang by the brake hose. 7. Remove the outboard brake shoe from the caliper by prying the shoe retaining clip over the raised area on the caliper. Slide the brake shoe down and off of the caliper. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4739 8. Pull the inboard brake shoe away from the caliper piston until the retaining clip is out of the cavity in the piston and remove the shoe. 9. Repeat the above procedure to the front brakes on the other side of the vehicle. CLEANING - DISC BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors. 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 disc brake shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. - For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. - Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were removed from. INSTALLATION - DISC BRAKE SHOES (FRONT) NOTE: Some vehicles use a different lining material on the front disc brake shoes than other vehicles. When new brake shoes are installed, be sure the brake shoes for the correct type of brake system are used. 1. Begin on one side of the vehicle. 2. Completely retract the caliper piston back into the bore of the caliper. This is required to gain the necessary shoe-to-rotor clearance for the caliper installation onto the steering knuckle. 3. Remove any protective paper from the noise suppression gasket on both the inner and outer brake shoes (if equipped). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4740 Inboard Brake Shoe 4. Install the inboard brake shoe into the caliper piston by firmly pressing the shoe in with the thumbs. Be sure the inboard brake shoe is positioned squarely against the face of the caliper Piston. Installing Outboard Brake Shoe 5. Slide the new outboard brake shoe onto the caliper. 6. Lubricate both steering knuckle caliper slide abutments with a liberal amount of Mopars Multipurpose Lubricant, or an equivalent. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4741 7. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top caliper slide abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower caliper slide abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 8. Install the caliper guide pin bolts and tighten them to a torque of 22 Nm (192 in. lbs.). 9. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 10. Repeat the above procedure to the front brakes on the other side of the vehicle. 11. Lower the vehicle. 12. Pump the brake pedal to set the brake shoes to the brake rotors, then check brake fluid level in master cylinder reservoir. Adjust brake fluid level as necessary. 13. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4742 Brake Pad: Service and Repair Rear REMOVAL- DISC BRAKE SHOES (REAR) NOTE: Before proceeding, Refer to Service Precautions. 1. Raise the vehicle. 2. Remove both rear tire and wheel assemblies from vehicle. 3. Begin on one side of the vehicle. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. 4. Remove the two caliper guide pin bolts. Caliper Removal/Installation 5. Remove the caliper assembly from the brake adapter by first rotating the top of the caliper away from the rotor, and then lifting the caliper assembly off the machined abutment on the adapter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4743 6. Hang the brake caliper from rear strut using wire or cord to prevent the weight of the caliper from damaging the brake hose. 7. Remove the outboard brake shoe from the caliper by prying the brake shoe retaining clip over the raised area on the caliper. Then slide the brake shoe down and off of the brake caliper. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4744 Removing Installing Inboard Brake Shoe 8. Pull the inboard brake shoe away from caliper piston until the retaining clip is free from the cavity in the piston. 9. Repeat the above procedure to the rear brakes on the other side of the vehicle. CLEANING - DISC BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors. 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 disc brake shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. - For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. - Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were removed from. INSTALLATION - DISC BRAKE SHOES (REAR) 1. Begin on one side of the vehicle. 2. Completely retract the caliper piston back into piston bore of the caliper. This is required to gain the necessary shoe-to-rotor clearance for the caliper installation onto the steering knuckle. 3. Remove any protective paper from the noise suppression gasket on both inner and outer brake shoe assemblies (if equipped). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4745 Removing Installing Inboard Brake Shoe 4. Install the inboard brake shoe into the caliper piston by firmly pressing the shoe in with the thumbs. Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston. 5. Slide the outboard brake shoe onto the caliper assembly. Be sure the retaining clip is squarely seated in the depressed areas on the caliper. 6. Lubricate both adapter caliper slide abutments with a liberal amount of Mopars Multipurpose Lubricant, or an equivalent. CAUTION: Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4746 Caliper Removal/Installation 7. Starting with the lower end, carefully lower the caliper and brake shoes over the brake rotor and catch the caliper's bottom edge behind the caliper slide abutment. Rotate the top of the caliper into mounting position on the adapter. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. 8. Carefully install the caliper guide pin bolts, then tighten them to a torque of 22 Nm (192 in. lbs.). 9. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 10. Repeat the above procedure to the rear brakes on the other side of the vehicle. 11. Lower the vehicle. 12. Pump the brake pedal to set the brake shoes to the brake rotors, then check brake fluid level in master cylinder reservoir. Adjust brake fluid level as necessary. 13. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Rotor Rear Rotor ROTOR THICKNESS 21.87 - 22.13 mm (0.861 - 0.871 in.) 8.75 - 9.25 mm (0.344 - 0.364 in.) MINIMUM ROTOR THICKNESS 20.4 mm (0.803 in.) 7.25 mm (0.285 in.) 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4750 Brake Rotor/Disc: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be checked and inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied until the rust wears away. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine (turn) the rotor if it will cause the rotor to fall below minimum thickness. Minimum thickness specifications are cast on the rotor's unmachined surface (or stamped into the hat section). Limits can also be found in specifications ROTOR THICKNESS VARIATION Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4751 Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor at 12 equal points around the rotor braking surface with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary beyond the specification listed in specifications, the rotor should be refaced or replaced. ROTOR 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 rotor runout on the vehicle, first remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adaptor, Special Tool SP-1910 on steering arm. The dial indicator plunger should contact braking surface of rotor approximately 25 mm (1 inch) from edge of rotor. Check lateral runout on both sides of the rotor, marking the low and high spots on both. Runout limits can be found in specifications. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4752 If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. Remove the rotor from the hub. NOTE: Clean the hub face surface before checking runout. This provides a clean surface to get an accurate indicator reading. Mount Dial Indicator, Special Tool C-3339, and Mounting Adaptor, Special Tool SP-1910, to the steering knuckle. Position the indicator stem so it contacts the hub face near the outer diameter. Care must be taken to position stem outside of the stud circle, but inside of the chamfer on the hub rim. Hub runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, the hub must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4753 If the hub runout does not exceed this specification, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud. Tighten nuts in the proper sequence and torque to specifications. Recheck brake rotor runout to see if the runout is now within specifications. If runout is not within specifications, reface or replace the brake rotor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation Brake Rotor/Disc: Service and Repair Brake Rotor - Removal and Installation Front Brake Rotor REMOVAL- BRAKE ROTOR (FRONT) 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. Remove the front disc brake caliper assembly from the brake rotor and store it out of the way. 4. Remove the clips retaining the brake rotor. 5. Remove the brake rotor by pulling it straight off the wheel mounting studs. INSTALLATION - BRAKE ROTOR (FRONT) 1. Install the brake rotor over the wheel mounting studs and onto the hub. 2. Install the front disc brake caliper. It may be necessary to retract the brake caliper piston back into the caliper to fit the shoes onto the rotor. 3. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 4. Lower the vehicle. 5. Pump the brake pedal before moving the vehicle to set the brake shoes to the brake rotor. Rear Brake Rotor REMOVAL- BRAKE ROTOR (REAR) 1. Raise the vehicle. 2. Remove the rear tire and wheel assembly. 3. Remove the rear disc brake caliper assembly from the brake rotor and store it out of the way. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 4756 4. Remove any clips retaining the brake rotor. 5. Remove the brake rotor by pulling it straight off the wheel mounting studs. INSTALLATION - BRAKE ROTOR (REAR) NOTE: Inspect the disc brake shoes and parking brake shoes before brake rotor installation. 1. Install the rear brake rotor over the wheel mounting studs and onto the hub. 2. Install rear disc brake caliper. 3. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 4. Adjust the parking brake shoes as necessary. 5. Lower the vehicle. 6. Pump the brake pedal before moving the vehicle to set the brake shoes to the brake rotor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 4757 Brake Rotor/Disc: Service and Repair Brake Rotor Machining STANDARD PROCEDURE - BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. On-Car Brake Lathe If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe, or replaced. The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. Minimum Brake Rotor Thickness Markings (Typical) NOTE: All rotors have markings for minimum allowable thickness cast on an unmachined surface of the rotor or stamped into the hat section. Minimum thickness specifications can also be found in the specifications. Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 4758 When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Specifications for brake rotor machining can be found in specification. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications DRUM BRAKE SHOE SUPPORT PLATE (REAR) Mounting Bolts 55 ft. lbs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4763 Backing Plate: Service and Repair SUPPORT PLATE DRUM BRAKE REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise the vehicle. 3. Remove the rear tire and wheel assembly from the vehicle. 4. Disconnect the rear brake flex hose from the wheel cylinder. 5. Remove the rear brake drum. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4764 6. Remove the dust cap from the rear hub and bearing. 7. Remove the nut holding the rear hub and bearing to the spindle. Remove the hub and bearing from the spindle. 8. Remove the rear brake shoes from the brake support plate. 9. Remove the parking brake actuator lever from the parking brake cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4765 10. Position a to inch wrench over the retainer fingers on the end of the parking brake cable. Compress the cable housing retaining fingers with the wrench, then pull the cable housing out of the support plate. Remove the wrench as the parking brake cable retainer is freed from the mounting hole in the brake support plate. 11. Remove the 4 brake support plate mounting bolts and washers. Separate brake support plate from rear suspension knuckle. 12. Remove the brake wheel cylinder attaching bolts. 13. Remove the brake wheel cylinder from the brake support plate. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Install a new O-ring at 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 support plate. 2. Install the wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 13 Nm (115 in. lbs.). 3. Install the brake support plate and gasket on rear suspension knuckle. Tighten the support plate mounting bolts to a torque of 75 Nm (55 ft. lbs.). 4. Insert the parking brake cable into its mounting hole in the brake support plate. Push the cable housing in until the retainer's fingers lock into place. 5. Hand start the brake flex hose tube fitting to the wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 in. lbs.). 6. Attach the parking brake cable to the parking brake actuator. 7. Install the rear brake shoe assemblies on the brake support plate. 8. Install the rear hub and bearing assembly on the spindle. Install a new hub and bearing retaining nut. Tighten the retaining nut to a torque of 217 Nm (160 ft. lbs.). Install dust cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4766 9. Install the brake drum. 10. Install the wheel and tire assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 11. Adjust the rear brake shoes. 12. Lower the vehicle. 13. Remove the brake pedal holding tool. 14. Bleed the wheel cylinder as necessary. 15. Road test the vehicle to make sure the brakes operate correctly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER To properly test the drum brake automatic adjuster, the aide of a helper inside the vehicle to apply the brakes will be necessary. 1. Raise the vehicle. 2. Remove the access plug from the rear adjustment slot in each brake support plate. 3. Insert a thin screwdriver in the adjustment slot and push back the adjustment lever. With the lever in this position, back the star wheel adjustment off approximately 10 notches. This will eliminate the possibility that the brake is at full adjustment, and can be adjusted no further. 4. Remove the screwdriver from the adjustment slot. 5. Watch the star wheel through the adjustment slot, while a helper applies the brake pedal. As the brake shoes apply, the adjustment lever should move downward, turning the star wheel. A definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly. If the star wheel does not move as indicated, the brake drum needs to be removed and further inspection of the rear brakes is necessary. 6. If the star wheel is operating properly, readjust the brakes. 7. Reinstall the adjustment slot access plug. 8. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 ........................................................................................................................................ ............................................................... .006" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4773 Brake Drum: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE DRUM With the drum off the vehicle, measure the drum for diameter variation (oval shape). The diameter variation 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°. Measure brake drum runout. Brake drum runout should be checked with the drum mounted on a brake lathe. Brake drum runout should not exceed 0.1524 mm (0.006 inch). If either of these measurements are not within specification, reface or replace the drum. Always replace the drum if machining will cause the diameter to exceed drum maximum diameter. All brake drums are marked with the maximum allowable brake drum diameter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation Brake Drum: Service and Repair Removal and Installation REMOVAL 1. Raise the vehicle. 2. Remove the rear tire and wheel assembly from the vehicle. 3. Remove the brake drum retaining clips (if equipped). 4. Remove the brake drum. NOTE: If the drum does not come off, further brake clearance can be obtained by backing off the brake automatic adjuster screw. Remove the rubber plug from the top of brake support plate. Rotate the automatic adjuster screw in an upward motion, using a screwdriver. INSTALLATION NOTE: Before installing the drum, inspect the brake shoe linings for wear, shoe alignment, and contamination. 1. Install the rear brake drum on rear hub and bearing. 2. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 3. Adjust the rear brake shoes as necessary. 4. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 4776 Brake Drum: Service and Repair Brake Drum Machining STANDARD PROCEDURE - BRAKE DRUM MACHINING If a brake drum is deeply scored or warped, it can be machined on a brake lathe equipped to machine brake drums. Follow the manufacturers instructions on the machining procedure. Measure the brake drum diameter before machining. If machining the drum will cause the drum to exceed maximum allowable diameter, do not machine the brake drum. It needs to be replaced. CAUTION: Do not machine the brake drum if it will cause the drum to exceed maximum allowable diameter. All brake drums are marked with the maximum allowable brake drum diameter. When machining, make sure the final finish feed cut is fine in order to avoid a screw effect on the brake shoes when the brakes are applied. This final feed cut specification varies from lathe manufacturer to lathe manufacturer. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Brake Shoe Thickness Specifications Brake Shoe: Specifications Brake Shoe Thickness Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Brake Shoe Thickness Specifications > Page 4781 Brake Shoe: Specifications Torque Specifications Drum Brake Shoe Support Plate Mounting Bolts ..................................................................................................................................... 75 Nm (55 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4782 Brake Shoe: Adjustments ADJUSTMENT- DRUM BRAKE SHOES 1. Verify the parking brake lever is in the fully released position. 2. Raise the vehicle. 3. Remove the rear brake adjusting hole rubber clue from the rear brake shoe support plate. 4. Insert a brake adjustment tool, or a screwdriver, through the adjusting hole in support plate and against the star wheel of the adjuster screw. Move the handle of tool downward to adjust the brake drag. Rotate the tire and wheel assembly while adjusting the adjuster screw. Continue to adjust the shoes until a slight drag is noticed when the tire and wheel assembly is rotated. NOTE: In the event the brake shoes are over-adjusted, the adjuster can be backed off using the following step. If not, proceed to step 6. 5. If the shoes are in the over-adjusted position, insert a thin screwdriver into brake adjusting hole and push back the adjusting lever out of engagement with star wheel. Take care not to bend the adjusting lever. While holding the adjusting lever out of engagement with star wheel, back off the star wheel until the tire and wheel assembly is free to turn without dragging. Repeat the adjustment procedure. 6. Install adjusting hole rubber plug. 7. Repeat the above adjustment procedure to the other side brakes. 8. Apply and release the park brake lever one time after the adjustment process is completed so the parking brakes can readjust themselves to the new brake shoe adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4783 Brake Shoe: Service and Repair REMOVAL- DRUM BRAKE SHOES (REAR) NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Remove both rear tire and wheel assemblies from the vehicle. 3. Begin on one side of the vehicle. 4. Remove the brake drum retaining clips (if equipped). 5. Remove the brake drum. 6. Remove the automatic adjustment lever-to brake shoe spring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4784 7. Remove the automatic adjustment lever from the brake shoe. 8. Remove the hold down clips and pins attaching the leading and trailing brake shoes to the brake support plate . Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4785 9. Remove the lower brake shoe-to-anchor plate return spring. 10. Remove the parking brake lever pin-to-brake shoe retaining clip . Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4786 11. Remove the leading and trailing brake shoes, upper return spring and automatic adjuster screw from the brake support plate as an assembly. 12. Disassemble the shoes completely once on the bench. 13. Repeat the above procedure to the rear brakes on the other side of the vehicle. CLEANING - DRUM BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DRUM BRAKE SHOES Rear brake shoe lining should show contact across the entire width of the lining and also from the heel to the toe of the lining. Replace the shoes if noted otherwise. Brake shoes with lack of contact at the toe or heel of the brake shoe lining may be improperly ground. Clean and inspect the brake support plate and shoe adjuster screw. Apply a thin coat of Mopar Multi-Purpose Lubricant or equivalent to the threads of the self-adjuster. Replace the adjuster screw if it is corroded. NOTE: Adjuster screws are different side-to-side. Left side adjuster screws have left-hand threads and right side adjuster screws have right-handed threads. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4787 If the old brake shoe return or hold down springs have overheated or are damaged, replace them. Overheating indications are paint discoloration or distorted end coils. INSTALLATION - DRUM BRAKE SHOES (REAR) NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Begin on one side of the vehicle. 2. Lubricate the eight shoe contact areas on the support plate and anchor using Mopar Multi-Purpose Lubricant or equivalent. 3. Assemble the front and rear brake shoe assembly, automatic adjuster screw, and upper return spring before installation on the vehicle. 4. Install the pre-assembled brake shoes, automatic adjuster screw and upper return spring on the brake support plate. 5. Install the wave washer on the pin of park brake lever. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4788 6. Install the pin on the parking brake lever into hole in rear brake shoe assembly. 7. Install both brake shoe-to-brake support plate hold down pins and clips. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4789 8. Install the lower brake shoe-to-anchor plate return spring. 9. Install the automatic adjustment lever on the leading brake shoe. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4790 10. Install the automatic adjustment lever-to brake shoe spring. 11. Adjust the brake shoes out until the drum lightly drags on the shoes when it is installed. Do not over-adjust the brakes. 12. Install the brake drum. 13. Repeat the above procedure to the rear brakes on the other side of the vehicle. 14. Install the tire and wheel assemblies. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 15. Adjust the rear brake shoes. 16. Lower the vehicle. 17. Road test vehicle stopping in both the forward and reverse directions. The automatic adjuster will continue to adjust the brakes during the road test of the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Drum Brake Wheel Cylinder Mounting Bolts ........................................................................................................................................ 13 Nm (115 in. lbs.) Drum Brake Wheel Cylinder Bleeder Screw ........................................................................................................................................... 10 Nm (89 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4794 Wheel Cylinder: Service and Repair WHEEL CYLINDERS DRUM BRAKE REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position . This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise the vehicle. 3. Remove the rear tire and wheel assembly. 4. Disconnect the rear brake flex hose from the wheel cylinder. 5. Remove the rear brake drum. 6. Remove the rear brake shoes from the brake support plate. NOTE: If the brake shoes are wet with grease or brake fluid, replace them. 7. Remove the brake wheel cylinder attaching bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4795 8. Remove the brake wheel cylinder from the brake support plate. INSPECTION With the 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. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Install a new O-ring at 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 assembly. 2. Install the wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 13 Nm (115 in. lbs.). 3. Hand start the rear brake flex hose tube fitting to wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 in. lbs.). 4. Install the rear brake shoes on the brake support plate. Replace them as necessary. 5. Install the rear brake drum onto the rear hub. 6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 7. Adjust the rear brakes. 8. Lower the vehicle. 9. Remove the brake pedal holder. 10. Bleed the wheel cylinder as necessary. 11. Road test the vehicle to make sure the brakes operate correctly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise. 2. Refer to one of the following depending on whether the master cylinder is a non-ABS unit Step a or an ABS unit Step b: a. Attach four Master Cylinder Bleed Tubes, Special Tool 8358-1, to the four ports of the master cylinder and tighten each in place. The bleed tubes for the ports pertaining to the rear brakes are made to attach to the proportioning valves screwed into the master cylinder. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. b. Attach Master Cylinder Bleed Tube, Special Tool 8358-1, to the primary port of the master cylinder and tighten in place. Attach Master Cylinder Bleed Tube, Special Tool 8358-2, to the secondary port of the master cylinder and tighten in place. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. 3. Fill the brake fluid reservoir with fresh Mopars brake fluid, or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel as a pushrod, press the pistons inward slowly applying brake pressure, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled out of the tubes and master cylinder bore. 5. Remove the bleed tubes from the master cylinder and plug the outlet ports. 6. Install the fill cap on the reservoir. 7. Remove the master cylinder from the vise. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4801 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. - Use only Mopar brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not pump the brake pedal at any time while a bleeder screw is open. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4802 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRBIII scan tool to the Data Link Connector. The connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRBIII, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRBIII. 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 YOURSELF AND 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. 5. Using the DRBIII, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4803 Brake Bleeding: Service and Repair Standard Procedure - Manual Bleeding MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least 1 full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4804 Brake Bleeding: Service and Repair Standard Procedure - Pressure Bleeding PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Following the same wheel circuit sequence as prescribed for manual bleeding. 1. Attach Adapter, Special Tool 6921, to the master cylinder reservoir. 2. Attach Bleeder Tank, Special Tool C-3496-B, or an equivalent, to the adapter on the master cylinder. 3. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 4-8 ounces of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Banjo Bolt ............................................................................................................. .................................................... 47 Nm (35 ft. lbs.) Disc Brake Caliper Adapter (To Knuckle) Rear .................................................................................................................................... 75 Nm (55 ft. lbs.) Disc Brake Caliper Guide Pin Bolts ...................................................................................................................................................... 22 Nm (192 in. lbs.) Disc Brake Caliper Bleeder Screw ......................................................................................................................................................... 15 Nm (125 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper Brake Caliper: Service and Repair Front Disc Brake Caliper REMOVAL- DISC BRAKE CALIPER (FRONT) NOTE: Before proceeding, Refer to Service Precautions. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise the vehicle. 3. Remove the front tire and wheel assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard these washers. Replace them with new ones. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4810 5. Remove the two brake caliper to steering knuckle guide pin bolts. 6. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side caliper) or bottom (left side caliper) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide abutment (on the knuckle) and brake rotor. DISASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. Removing Inner Sleeve From Bushing 1. With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4811 2. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. DISASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) Before disassembling the brake caliper, clean and inspect it. CALIPER PISTON REMOVAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CALIPER SEAL REMOVAL CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. To disassemble the caliper, mount it in a vise equipped with protective jaws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4812 2. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 3. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore. Discard the old seal. 4. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4813 5. 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 the equivalent to hone the bore. Do not overhone the bore. Don not increase the diameter of the bore more than 0.0254 mm (0.001 inch). If the bore does not clean up within this specification, a new caliper housing should be installed. NOTE: During the honing procedure, 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 bore with fresh clean brake fluid; wipe it dry with a clean, lint free cloth and then clean it a second time. 6. Inspect the caliper piston for pitting, scratches, or any physical damage. Replace the piston if there is evidence of scratches, pitting or physical damage. CLEANING - DISC BRAKE CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopars Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - DISC BRAKE CALIPER Inspect the disc brake caliper for the following: Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4814 Folded Caliper Guide Pin Bushing 1. Fold the guide pin bushing in half lengthwise at the solid middle section. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4815 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. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar Dielectric Grease or an equivalent. 5. Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve. 6. Holding the convoluted boot on the opposite end of the bushing, push the steel sleeve through the bushing until the bushing boot is fully seated into the seal groove on that end of sleeve . Install the other end bushing boot into the groove on that end of the bushing sleeve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4816 7. Verify both ends of the bushing are seated in the sleeve groves. When the sleeve is seated properly into the bushing, the sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. ASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) NOTE: Never use an old piston seal. Installing New Piston Seal In Caliper 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4817 Installing Piston Into Caliper Bore 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689, and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper. 7. Install the brake shoes. 8. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION - DISC BRAKE CALIPER (FRONT) 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 caliper slide abutments with a liberal amount of Mopars Multipurpose Lubricant, or an equivalent. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4818 3. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top caliper slide abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower caliper slide abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 4. Install the caliper guide pin bolts and tighten them to a torque of 22 Nm (192 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4819 5. Install the banjo bolt connecting the brake hose to the brake caliper. Install NEW washers with the banjo bolt. Place one NEW washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to a torque of 48 Nm (35 ft. lbs.). 6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Remove the brake pedal holding tool. 9. Bleed the caliper as necessary. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4820 Brake Caliper: Service and Repair Rear Disc Brake Caliper REMOVAL- DISC BRAKE CALIPER (REAR) 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 2. Raise the vehicle. 3. Remove the rear tire and wheel assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard these washers. Replace them with new ones. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the shoes and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4821 5. Remove the two caliper guide pin bolts. Caliper Removal/Installation 6. Remove the caliper assembly from the brake adapter by first rotating the top of the caliper away from the rotor, and then lifting the caliper assembly off the machined abutment on the adapter. DISASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4822 1. With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing. 2. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. DISASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) Before disassembling the brake caliper, clean and inspect it. CALIPER PISTON REMOVAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4823 NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CALIPER SEAL REMOVAL CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. To disassemble the caliper, mount it in a vise equipped with protective jaws. Fig. 10 Dust Boot Removal 2. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4824 Removing Piston Seal From Caliper 3. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore. Discard the old seal. 4. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 5. 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 the equivalent to hone the bore. Do not over-hone the bore. Don not increase the diameter of the bore more than 0.0254 mm (0.001 inch). If the bore does not clean up within this specification, a new caliper housing should be installed. NOTE: During the honing procedure, 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 bore with fresh clean brake fluid; wipe it dry with a clean, lint free cloth and then clean it a second time. 6. Inspect the caliper piston for pitting, scratches, or any physical damage. Replace the piston if there is evidence of scratches, pitting or physical damage. CLEANING - DISC BRAKE CALIPER Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4825 WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopars Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - DISC BRAKE CALIPER Inspect the disc brake caliper for the following: Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY- DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Folded Caliper Guide Pin Bushing 1. Fold the guide pin bushing in half lengthwise at the solid middle section. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4826 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper mounting boss using your fingers . 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar Dielectric Grease or an equivalent. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4827 Fig 7 Installing Caliper Sleeves 5. Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve. 6. Holding the convoluted boot on the opposite end of the bushing, push the steel sleeve through the bushing until the bushing boot is fully seated into the seal groove on that end of sleeve. Install the other end bushing boot into the groove on that end of the bushing sleeve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4828 Fig 8 Installed Caliper Bushing Sleeve 7. Verify both ends of the bushing are seated in the sleeve groves. When the sleeve is seated properly into the bushing, the sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. ASSEMBLY- DISC BRAKE CALIPER (PISTON AND SEAL) NOTE: Never use an old piston seal. 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. Installing New Piston Seal In Caliper 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4829 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. Installing Piston Into Caliper Bore 6. Using a hammer and Installer, Special Tool C-4689, and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper. 7. Install the brake shoes. 8. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION - DISC BRAKE CALIPER (REAR) NOTE: Step (1) below is only required when installing the disc brake caliper after new brake shoes have been installed. 1. Completely retract the caliper piston back into piston bore of the caliper. 2. Lubricate both adapter caliper slide abutments with a liberal amount of Mopars Multipurpose Lubricant, or an equivalent. CAUTION: Use care when installing the caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Disc Brake Caliper > Page 4830 Caliper Removal/Installation 3. Starting with the lower end, carefully lower the caliper and brake shoes over the brake rotor and catch the caliper's bottom edge behind the caliper slide abutment. Rotate the top of the caliper into mounting position on the adapter. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. 4. Carefully install the caliper guide pin bolts, then tighten them to a torque of 22 Nm (192 in. lbs.). 5. Install the banjo bolt connecting the brake hose to the brake caliper . Install NEW washers with the banjo bolt. Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to a torque of 48 Nm (35 ft. lbs.). 6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Remove the brake pedal holding tool. 9. Bleed the caliper as necessary. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Bring the fluid level up to the requirements described on the side of the brake reservoir. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 4835 Brake Fluid: Fluid Type 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4836 Brake Fluid: Service Precautions WARNING: Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident. CAUTION: DO not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4837 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - 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 including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4838 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs are marked, FULL and MIN, indicating the allowable brake fluid level range in the master cylinder brake fluid reservoir. 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. Although there is a range, the preferred level is FULL. If necessary, adjust the brake fluid level to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4842 Fig. 37 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4843 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4844 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4845 Brake Fluid Level Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4846 Brake Fluid Level Sensor/Switch: Service Precautions CAUTION: An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system. The entire brake hydraulic system should be checked for evidence of a leak. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4847 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch is located in the left side of the brake fluid reservoir on the master cylinder. It is clipped into the reservoir. It can be removed from the reservoir and replaced if necessary. OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder reservoir has dropped below an acceptable level. As the fluid drops below the designed level, the fluid level switch closes and grounds the red BRAKE warning indicator circuit. This turns on the red BRAKE warning indicator. At this time, the master cylinder brake fluid reservoir must be checked and filled to the full mark with DOT 3 brake fluid. Check the entire brake hydraulic system for evidence of a leak. CAUTION: An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system. The entire brake hydraulic system should be checked for evidence of a leak. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4848 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir. 2. Push together the retaining tabs holding the brake fluid level switch in place in the brake fluid reservoir. 3. Pull the brake fluid level switch out the other side of the reservoir. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Align the brake fluid level switch with its mounting hole on the left side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs are expanded on the other side of the reservoir, locking it in place. 2. Connect the brake fluid level switch wiring connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Hose Banjo Bolt (To Caliper) ..................................................................................................................................................... 24 Nm (210 in. lbs.) Brake Tube Nuts ...................................................................................................... .............................................................................. 17 Nm (145 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4852 Brake Hose/Line: Description and Operation DESCRIPTION - BRAKE TUBES AND HOSES The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses are made of reinforced rubber with fittings at each end. OPERATION - BRAKE TUBES AND HOSES The purpose of the brake tubes and flex hoses is to transfer brake fluid pressure, developed by the master cylinder to the brakes at each wheel of the vehicle. The flex hoses connect the chassis brake tubes which are mounted to the vehicle's underbody to the brake at each wheel, allowing for movement of the vehicle's suspension. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4853 Brake Hose/Line: Testing and Inspection INSPECTION - BRAKE TUBES AND 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. 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications PROPORTIONING VALVE: (non-ABS vehicles) Material ................................................................................................................................................ ............................................................. Aluminum Function ................................................................ ............................................................................................................... Fixed Pressure Proportioning Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4857 Brake Proportioning/Combination Valve: Description and Operation PROPORTIONING VALVE DESCRIPTION NOTE: Only vehicles without antilock brakes have proportioning valves. Vehicles with antilock brakes have Electronic Variable Brake Proportioning (EVBP) that is built into the Integrated Control Unit (ICU). Proportioning valves balance front to rear braking by controlling the brake fluid hydraulic pressure to the rear brakes. Under light pedal application, the proportioning valve allows normal fluid flow to the rear brakes. Under higher pedal effort, the valve reduces fluid pressure to the rear brakes. The non-antilock master cylinder is a four-outlet design with two screw-in proportioning valves attached directly to the master cylinder housing. One proportioning valve controls each rear brake. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4858 Brake Proportioning/Combination Valve: Testing and Inspection DIAGNOSIS AND TESTING - PROPORTIONING VALVE 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 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 skids first is essential. Before testing the proportioning valve in question, inspect the rear brake linings for contamination or for replacement shoes not meeting the OEM brake lining material specifications. The proportioning valve should always be tested prior to being replaced. The in-line proportioning valves used on this vehicle require special pressure fittings to test the proportioning valves 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. PROPORTIONING VALVE TEST The test procedure is the same for either rear proportioning valve. After road testing the vehicle to determine which wheel skids first, follow the procedure below for testing the suspect proportioning valve. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4859 2. Use the figure shown to determine which proportioning valve needs to be tested. 3. Remove the hydraulic brake tube from the proportioning valve controlling the rear wheel of the vehicle that has premature wheel skid. 4. Remove the proportioning valve from its outlet port on the master cylinder. CAUTION: Be sure the pressure test fittings being installed into master cylinder and proportioning valve, have the correct thread sizes needed. 5. Install the Brake Pressure Adapters, Special Tool 8644 and 6805-3 onto the proportioning valve. 6. Install the proportioning valve (with tools) back into the outlet port on the master cylinder. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4860 7. Attach a Pressure Gauge, Special Tool C 4007-A, to each pressure adapter. 8. Remove the brake pedal holding tool. Bleed any air out of the pressure gauge hoses at the pressure gauge. 9. With the aid of a helper, apply pressure to the brake pedal until the reading on proportioning valve inlet gauge is at the target inlet pressure shown in the BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS table following this procedure. If the inlet gauge pressure overshoots its target pressure when the pedal is depressed, release the brake pedal, relieving the pressure in the system, before reapplying the pedal to reach the target pressure at the inlet gauge. This is necessary to get an accurate reading of the outlet pressure. 10. Once inlet pressure has been achieved, check the pressure reading on the proportioning valve outlet gauge. If the proportioning valve outlet pressure does not agree with value shown in the table, replace the proportioning valve. If proportioning valve is within pressure specifications, the valve is good and does not require replacement. 11. Reinstall the brake holding tool on the brake pedal and remove the test equipment from the vehicle. 12. Remove the tools from the valve. 13. Install the proportioning valve in the master cylinder and hand tighten until the proportioning valve is fully installed and its O-ring seal is seated into the master cylinder. Torque the proportioning valve to 17.5 Nm (155 in. lbs.). 14. Install the brake tube on the proportioning valve. Torque the tube nut to 17 Nm (145 in. lbs.). 15. Bleed the affected brake line. Brake Proportioning Valve Applications and Pressure Specifications Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4861 Brake Proportioning/Combination Valve: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. Brake Pedal Holding Tool 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position . This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Disconnect the brake tube from the proportioning valve requiring removal. 3. Unscrew the Proportioning valve from the master cylinder. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Lubricate the O-ring on the proportioning valve. Make sure the O-ring on the proportioning valve is new. 2. Install the proportioning valve in its master cylinder port. Tighten the proportioning valve to a torque of 17.5 Nm (155 inch lbs.). 3. Connect the brake tube to the proportioning valve. Tighten the tube nut to a torque of 17 Nm (145 inch lbs.). 4. Remove the brake pedal holder. 5. Bleed the affected brake line. 6. Road test the vehicle to ensure proper operation of the brakes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS HYDRAULIC CONTROL UNIT Hydraulic Tube Fitting Type ........................................................................................................................................................ SAE 45° Inverted Flare Inlet Port Threads .......................................................................................... ........................................................................................................ 7/16-24 Outlet Port Threads Left Front and Left Rear ...................................................................................................................................................... 7/16-24 Outlet Port Threads - Right Front and Right Rear ................................................................................................................................................... 3/8-24 BRAKE FASTENER TORQUE ABS ICU Mounting Bolts (To Bracket) .............................................................................................................................................. 11 Nm (97 in. lbs.) ABS ICU Mounting Bolts (To Frame) ............................................................................................................................................... 23 Nm (200 in. lbs.) ABS CAB Mounting Screws (To HCU) ............................................................................................................................................. 2 Nm (17 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4865 Hydraulic Control Assembly - Antilock Brakes: Locations Hydraulic Control Unit Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU) The Hydraulic Control Unit (HCU) is mounted to the CAB as part of the ICU. The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are spring loaded in the open position and the outlet valves are spring-loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/ motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. There are two noise dampening chambers in the HCU on this vehicle equipped with traction control. PUMP/MOTOR There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the CAB. The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, these pistons are used to purge fluid from the accumulators back into the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The pump motor is also used to build pressure when the system goes into traction control mode. The CAB may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. OPERATION - HYDRAULIC CIRCUITS AND VALVES The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4868 following paragraphs explain how this works. For purposes of explanation only, it is assumed that only the right front wheel is experiencing antilock braking; the following diagrams show only the right front wheel in an antilock braking operation. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram shows the vehicle in the normal braking mode of the base brake hydraulic system. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal; this builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4869 The hydraulic diagram shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4870 Hydraulic Control Assembly - Antilock Brakes: Description and Operation ICU (Integrated Control Unit) ICU (INTEGRATED CONTROL UNIT) DESCRIPTION The Hydraulic Control Unit (HCU) and the Controller Antilock Brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU is located on the driver's side of the vehicle, below the master cylinder. The ABS with traction control ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two hydraulic shuttle valves, two traction control valves, valve block, fluid accumulators, a pump, and an electric pump/motor. The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any components of the HCU or CAB. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4871 Hydraulic Control Assembly - Antilock Brakes: Service and Repair INTEGRATED CONTROL UNIT (ICU) NOTE: If servicing the Controller Antilock Brake (CAB) only, the CAB can be serviced with the ICU mounted in the vehicle. REMOVAL- ICU NOTE: Before proceeding, Refer to Service Precautions. Brake Pedal Holding Tool Installed 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Disconnect negative (ground) cable from the battery and isolate the cable. 3. Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place. 4. Remove the one nut and one bolt securing the air cleaner box in place, then disconnect the wiring harness connector at the air inlet sensor. 5. Lift the air cleaner box upward enough to clear its grommeted alignment post, then move the air cleaner box forward just enough to access the battery tray mounting bolts. 6. Remove the 2 bolts, then the 2 nuts mounting the battery tray to its bracket. Remove the battery tray. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4872 7. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs in the master cylinder outlet ports. 8. Disconnect the 24-way connector from the Controller Antilock Brake (CAB) mounted on the Integrated Control Unit (ICU) and move it out of the way. The connector is disconnected by pulling outward on the connector lock. This will unlock and raise the 24-way connector out of the socket on the CAB. 9. Tag the brake tubes coming from the master cylinder as primary and secondary. This is done to avoid mix-up once the tubes are removed from the vehicle. 10. Disconnect and remove the primary and secondary brake tubes coming from the master cylinder at the ICU Hydraulic Control Unit (HCU). 11. Disconnect the brake tubes going to each individual brake at the HCU. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4873 12. Remove the 3 bolts attaching the ICU to its mounting bracket. 13. Remove the ICU from the vehicle. 14. If the CAB and HCU must be separated, Refer to ICU (INTEGRATED CONTROL UNIT) - DISASSEMBLY. DISASSEMBLY- ICU NOTE: To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this vehicle, the entire Integrated Control Unit (ICU) needs to be removed from the vehicle. The CAB can then be separated from the HCU. 1. Disconnect the pump/motor wiring harness from the CAB. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4874 2. Remove the 4 bolts attaching the CAB to the HCU3). 3. Remove the CAB from the HCU. ASSEMBLY- ICU Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4875 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU). Tighten the CAB mounting bolts to a torque of 2 Nm (17 in. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4876 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle. INSTALLATION- ICU 1. Install the ICU onto its mounting bracket. 2. Install the 3 bolts attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 in. lbs.) Brake Pedal Holding Tool Installed 3. Install the four brake tubes going to the brakes into their respective outlet ports on the ICU HCU. Using a crow foot on a torque wrench, tighten the four brake tube nuts to a torque of 17 Nm (145 in. lbs.). NOTE: When installing the brake tubes from the master cylinder on the HCU, the brake tube with the small tube nut is to be installed in the forward-most port on the HCU with the small end going toward the master cylinder secondary port. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4877 4. Install the primary and secondary brake tubes from the master cylinder onto the HCU. Do not completely tighten the primary and secondary tubes at this time. 5. Connect the primary and secondary brake tubes to the master cylinder ports. 6. Using a crow foot on a torque wrench, tighten the primary and secondary brake tube nuts at both the master cylinder and HCU to a torque of 17 Nm (145 in. lbs.). CAUTION: Before installing the 24-way connector in the CAB, be sure the seal is properly installed in the connector. 7. Install the 24-way connector into the socket of the CAB as follows: - Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible. - When the connector is fully seated into the CAB socket, push the connector lock inward. This pulls the connector into the socket of the CAB and locks it in the installed position. 8. Position the battery tray back in place. Install the two bolts, then the two nuts mounting the battery tray to its bracket. Tighten the two bolts and nuts to a torque of 15 Nm (135 in. lbs.). 9. Reinstall the air cleaner box onto its grommeted alignment post. 10. Install the one nut and one bolt securing the air cleaner box in place, then connect the wiring harness connector at the air inlet sensor. 11. Install the battery and clamp it in place. Tighten the hold-down clamp bolt to a torque of 12 Nm (105 in. lbs.). 12. Connect the positive, then the negative (ground) cable on the battery. NOTE: The ICU may need to be initialized using the DRBIII scan tool after ICU installation. Refer to Appropriate Diagnostic Information. 13. Bleed the base brakes and ABS hydraulic systems. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 4878 14. Fill the master cylinder to the proper fill level. 15. Road test the vehicle to ensure proper operation of the base and antilock brake systems. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications MASTER CYLINDER Mounting Studs .................................................................................................................................... .............................................................. M8 x 1.25 Diaphragm Size/Type .......................................... .................................................................................................................................... 205 mm Tandem Type ...................................................................................................................................... ........................................................................ Dual Tandem Body Material ....................................... ........................................................................................................................................... Anodized Aluminum Reservoir Material .............................................................................................................. ......................................................................... Polypropelene MASTER CYLINDER BORE STROKE AND SPLIT Non-ABS ........................................................................................................................................................ 22.23 mm x 34.0 mm (0.875 in. x 1.34 in.) ABS .................................................................................. .............................................................................. 23.82 mm x 34.0 mm (0.937 in. x 1.34 in.) Displacement Split ............................................................................................................................... ..................................................................... 50/50 MASTER CYLINDER FLUID OUTLET PORTS Tube Fitting Type ................................................................................................................................. ........................................ SAE 45° Inverted Flare W/ABS - Primary Tube Nut Thread ...................... ................................................................................................................................................ 7/16-24 W/ABS - Secondary Tube Nut Thread ................................................................................................ .................................................................... 3/8-24 W/O ABS - All Tube Nut Threads ........................ ................................................................................................................................................ 7/16-24 BRAKE FASTENER TORQUE Master Cylinder Mounting .................................................................................................................... ............................................. 18 Nm (160 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4882 Brake Master Cylinder: Description and Operation DESCRIPTION Two different master cylinders are used on this vehicle. Vehicles without Antilock Brakes (ABS) use a standard compensating-port master cylinder, while vehicles equipped with ABS use a center-valve design master cylinder. ABS vehicles, equipped with rear disc brakes, use a master cylinder with a 23.82 mm (0.937 inch) bore diameter, while non-ABS vehicles, equipped with rear disc brakes, use a 22.23 mm (0.875 inch) bore diameter master cylinder. The ABS master cylinder is a two-outlet design and the brake tubes from these primary and secondary outlet ports lead directly to the Integrated Control Unit (ICU) before going to each wheel brake. The non-ABS master cylinder is a four-outlet design (one for each wheel brake) with two screw-in proportioning valves (one for each rear wheel brake). One is attached directly to the inboard side of the master cylinder housing while the other is attached to the bottom. Both type master cylinders mount to the power brake booster using two nuts. They both have a seal on the rear of the mounting flange to seal vacuum in the booster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4883 The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and also has threaded ports with seats for hydraulic brake line connections. The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake fluid to the master cylinder when it is required. The reservoir is made of see-through plastic and it houses the brake fluid level switch. A removable brake fluid level switch is mounted in the left side. OPERATION When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake pressure through the proportioning valves (on non-ABS vehicles) and chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly. The non-ABS master cylinder's primary outlet ports supply hydraulic pressure to the right front and left rear brakes while the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. ABS equipped master cylinder outlet ports supply hydraulic pressure to the ABS Integrated Control Unit (ICU) where it is distributed to the individual wheel brakes. The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on both sides of the diaphragm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise. 2. Refer to one of the following depending on whether the master cylinder is a non-ABS unit Step a or an ABS unit Step b: a. Attach four Master Cylinder Bleed Tubes, Special Tool 8358-1, to the four ports of the master cylinder and tighten each in place. The bleed tubes for the ports pertaining to the rear brakes are made to attach to the proportioning valves screwed into the master cylinder. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. b. Attach Master Cylinder Bleed Tube, Special Tool 8358-1, to the primary port of the master cylinder and tighten in place. Attach Master Cylinder Bleed Tube, Special Tool 8358-2, to the secondary port of the master cylinder and tighten in place. Position the other end of the tubes into the master cylinder reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. 3. Fill the brake fluid reservoir with fresh Mopars brake fluid, or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel as a pushrod, press the pistons inward slowly applying brake pressure, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled out of the tubes and master cylinder bore. 5. Remove the bleed tubes from the master cylinder and plug the outlet ports. 6. Install the fill cap on the reservoir. 7. Remove the master cylinder from the vise. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4886 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation LHD With ABS REMOVAL - LHD WITH ABS NOTE: Before proceeding, Refer to WARNING. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place. 4. Disconnect the wiring harness connector from the brake fluid level switch on the master cylinder reservoir. 5. Disconnect the primary and secondary brake tubes from master cylinder. Install plugs in the master cylinder outlet ports. 6. Clean the area around where the master cylinder attaches to the power brake booster using a suitable brake cleaner such as Mopars Brake Parts Cleaner or an equivalent. 7. Remove the 2 nuts attaching master cylinder to power brake booster. 8. Slide the master cylinder straight out of the power brake booster. INSTALLATION - LHD WITH ABS NOTE: The master cylinder must be bled before installing it on the vehicle. 1. Bleed the master cylinder before installing it on the vehicle. 2. Inspect and wipe clean the O-ring vacuum seal on the master cylinder rear mounting flange to ensure a good vacuum seal once installation is complete. Replace as necessary. 3. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster. 4. Position the master cylinder on the studs of power brake vacuum booster aligning the booster push rod with the master cylinder push rod. Carefully push the master cylinder onto the studs until it contacts the face of the booster. 5. Install the two master cylinder mounting nuts. Tighten the mounting nuts to a torque of 18 Nm (160 inch lbs.). 6. Connect the primary and secondary brake tubes to the master cylinder primary and secondary ports. Tighten the nuts to a torque of 17 Nm (145 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4887 inch lbs.). 7. Install the wiring harness connector on the master cylinder reservoir fluid level switch. 8. Install the battery and clamp in place. 9. Connect the positive, then the negative (ground) cable on the battery. 10. Fill the master cylinder to the proper level. 11. Pump the brake pedal several times, then check brake fluid level in master cylinder reservoir. Adjust brake fluid level as necessary. CAUTION: It will be necessary to bleed the entire base hydraulic system if the brake system has been open to air for an excessive amount of time or air is present in the lines. 12. Check for leaks. 13. Road test the vehicle to ensure proper operation of the base and antilock brake systems. LHD Without ABS REMOVAL - LHD WITHOUT ABS NOTE: Before proceeding, Refer to WARNING. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place. 4. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4888 5. Disconnect the two brake tubes from the master cylinder, and two brake tubes from the proportioning valves. Install plugs at all of the open brake tube outlets on the master cylinder. 6. Clean the area around where the master cylinder attaches to the power brake booster using a suitable brake cleaner such as Mopar Brake Parts Cleaner or an equivalent. 7. Remove the two nuts attaching the master cylinder to the power brake booster. 8. Slide the master cylinder straight out of the power brake booster. 9. To remove the proportioning valves, unthread each from the master cylinder. INSTALLATION - LHD WITHOUT ABS NOTE: The master cylinder must be bled before installing it on the vehicle. 1. If removed, install the proportioning valves in their master cylinder ports. The valves are identical, so they can be installed in either master cylinder port going to the rear brakes. Make sure the O-rings on the proportioning valves are new. 2. Bleed the master cylinder before installing it on the vehicle. 3. Inspect and wipe clean the O-ring vacuum seal on the master cylinder rear mounting flange to ensure a good vacuum seal once installation is complete. Replace as necessary. 4. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster. 5. Position the master cylinder on the studs of the power brake booster, aligning the push rod of the power brake booster with master cylinder piston push rod. Carefully push the master cylinder onto the studs until it contacts the face of the booster. 6. Install the two master cylinder mounting nuts and tighten each to a torque of 18 Nm (160 inch lbs.). 7. Connect the four brake tubes to the master cylinder and proportioning valve ports. Tighten all tube nuts to a torque of 17 Nm (145 inch lbs.). 8. Connect the brake fluid level switch wiring connector. 9. Install the battery and clamp it in place. 10. Connect the positive, then the negative (ground) cable on the battery. 11. Fill the master cylinder to the proper level. 12. Pump the brake pedal several times, then check brake fluid level in master cylinder reservoir. Adjust brake fluid level as necessary. CAUTION: It will be necessary to bleed the entire base hydraulic system if the brake system has been open to air for an excessive amount of time or air is present in the lines. 13. Check for leaks. 14. Road test the vehicle to ensure proper operation of the brakes. RHD REMOVAL- RHD NOTE: Before proceeding, Refer to WARNING. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4889 3. Disconnect the brake fluid level switch wiring connector. 4. Remove the brake lines from the master cylinder. 5. Remove the (2) master cylinder mounting nuts. 6. Slide the master cylinder assembly straight out of the power brake booster. INSTALLATION - RHD NOTE: The master cylinder must be bled before installing it on the vehicle. 1. If removed, install the proportioning valves in their master cylinder ports. The valves are identical, so they can be installed in either master cylinder port going to the rear brakes. Make sure the O-rings on the proportioning valves are new. 2. Bleed the master cylinder before installing it on the vehicle. 3. Inspect and wipe clean the O-ring vacuum seal on the master cylinder rear mounting flange to ensure a good vacuum seal once installation is complete. Replace as necessary. 4. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster. 5. Slide the master cylinder assembly straight in the power brake booster. 6. Install the (2) master cylinder retaining nuts. Torque the nuts to 18 Nm (160 inch lbs.). 7. Install the brake lines on the master cylinder. Torque the tube nuts to 17 Nm (145 inch lbs.). 8. Connect the brake fluid level switch wiring connector. 9. Fill the master cylinder to the proper level. 10. Pump the brake pedal several times, then check brake fluid level in master cylinder reservoir. Adjust brake fluid level as necessary. CAUTION: It will be necessary to bleed the entire base hydraulic system if the brake system has been open to air for an excessive amount of time or air is present in the lines. 11. Check for leaks. 12. Road test the vehicle to ensure proper operation of the brakes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4890 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation FLUID RESERVOIR REMOVAL NOTE: Before proceeding, Refer to Service Precautions. - The master cylinder does not need to be removed from the power brake booster for removal and installation of the brake fluid reservoir. 1. Clean the master cylinder housing and brake fluid reservoir exterior surfaces. 2. Remove the brake fluid reservoir cap. Using a clean syringe or siphoning tool, empty as much brake fluid as possible from the reservoir. 3. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir. 4. Remove the two plastic pins holding the reservoir to the master cylinder. 5. Lift the reservoir from the master cylinder casting. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4891 6. Remove the grommets (O-rings) sealing the reservoir to the master cylinder housing. INSTALLATION 1. Install NEW sealing grommets (O-rings) in the master cylinder housing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4892 2. Lubricate the sealing grommets with fresh clean DOT 3 brake fluid. Place the reservoir in position over the grommets making sure the filler hole is towards the front of the vehicle. Seat the reservoir into the grommets. While holding the reservoir firmly against the grommets, install new plastic pins through their mounting holes until they protrude out the other side of the master cylinder reservoir. 3. Connect the brake fluid level switch wiring connector. 4. Fill the reservoir with fresh clean DOT 3 brake fluid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Drum Brake Wheel Cylinder Mounting Bolts ........................................................................................................................................ 13 Nm (115 in. lbs.) Drum Brake Wheel Cylinder Bleeder Screw ........................................................................................................................................... 10 Nm (89 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4896 Wheel Cylinder: Service and Repair WHEEL CYLINDERS DRUM BRAKE REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position . This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise the vehicle. 3. Remove the rear tire and wheel assembly. 4. Disconnect the rear brake flex hose from the wheel cylinder. 5. Remove the rear brake drum. 6. Remove the rear brake shoes from the brake support plate. NOTE: If the brake shoes are wet with grease or brake fluid, replace them. 7. Remove the brake wheel cylinder attaching bolts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4897 8. Remove the brake wheel cylinder from the brake support plate. INSPECTION With the 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. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Install a new O-ring at 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 assembly. 2. Install the wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 13 Nm (115 in. lbs.). 3. Hand start the rear brake flex hose tube fitting to wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 in. lbs.). 4. Install the rear brake shoes on the brake support plate. Replace them as necessary. 5. Install the rear brake drum onto the rear hub. 6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 7. Adjust the rear brakes. 8. Lower the vehicle. 9. Remove the brake pedal holder. 10. Bleed the wheel cylinder as necessary. 11. Road test the vehicle to make sure the brakes operate correctly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments ADJUSTMENT NOTE: The parking brake shoes used in the drum-in-hat park brake system do not automatically adjust to compensate for brake shoe lining wear. Therefore, it is necessary to manually adjust the parking brake shoes. 1. Verify the parking brake lever is in the released position. 2. Raise the vehicle. 3. Remove the rubber plug from the adjusting hole in the disc brake caliper adapter. 4. Adjust the parking brakes. Use the first bullet point for the adjustment of the left side parking brake shoes. Use the second bullet point for the adjustment of the right side parking brake shoes. ^ Insert a medium size screwdriver through adjustment hole in the left backing plate. Position the screwdriver against the star wheel on the parking brake shoe adjuster. Using the screwdriver, rotate the star wheel downward until a slight drag is noticed when turning the rear tire and wheel assembly. Then, using the screwdriver, slowly rotate the star wheel upward, backing off the adjuster, just enough to allow the rear tire and wheel assembly to rotate without the parking brake shoes dragging. Do not back off the adjuster star wheel more than two clicks past the point of no drag. The parking brake shoe-to-drum clearance is now properly set. ^ Insert a medium size screwdriver through adjustment hole in the right backing plate. Position the screwdriver against the star wheel on the parking brake shoe adjuster. Using the screwdriver, rotate the star wheel upward until a slight drag is noticed when turning the rear tire and wheel assembly. Then, using the screwdriver, slowly rotate the star wheel downward, backing off the adjuster, just enough to allow the rear tire and wheel assembly to rotate without the parking brake shoes dragging. Do not back off the adjuster star wheel more that two clicks past the point of no drag. The parking brake shoe-to-drum clearance is now properly set. 5. Install the rubber plug in the adjusting holes of the disc brake caliper adapter. 6. Lower the vehicle until the rear tires are just clearing the floor. 7. Reach inside the vehicle and fully apply and release the park brakes two times after adjusting the parking brake shoes. 8. With the parking brake lever in the fully applied position, attempt to hand rotate each rear tire and wheel assembly to ensure that the parking brake shoes are working. 9. With the parking brake lever in the released position, hand rotate each rear tire and wheel assembly to ensure that the parking brake shoes are not dragging. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4902 Parking Brake Cable: Service and Repair PARKING BRAKE CABLES REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. The procedure below applies to either of the two rear parking brake cables. 1. Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released. 2. Fully apply the parking brake lever, then shift the transmission into neutral. 3. Remove the screws attaching the center console, then remove the center console. 4. Lower the parking brake lever handle to the released position. 5. Grasp the parking brake lever output cable by hand and pull upward. Continue pulling on the cable until a pin punch can be inserted through the hole in the lever mechanism sector gear and the hole in the right side of its mounting bracket. This will lock the parking brake automatic adjustment mechanism in place and take tension off the parking brake cables. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4903 6. Remove both rear parking brake cables from the parking brake cable equalizer. 7. Remove the rear seat cushion from the vehicle. 8. Fold the rear carpeting forward to expose the parking brake cables at the end of the rear floor. 9. Install the box end of a to inch wrench over the parking brake cable retainer. Push the wrench onto the retainer until the retainer fingers are collapsed. From under the carpeting, grasp the parking brake cable housing and pull cable straight out of the bracket attached to the floor. 10. Raise the vehicle. 11. Remove the rear tire and wheel assembly from the vehicle. 12. On vehicles equipped with rear drum brakes, remove the brake drum. 13. On vehicles equipped with rear disc brakes: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4904 - Remove the disc brake caliper guide pin bolts, then the caliper from disc brake adapter. - Hang the caliper out of the way using a wire hanger or cord. - Remove the brake rotor from the rear hub and bearing. 14. Remove the dust cap from the rear hub and bearing. 15. Remove the hub and bearing retaining nut from the knuckle spindle, then remove the hub and bearing. 16. On vehicles equipped with rear disc brakes, remove the upper return spring, both shoe hold-down clips, then spread the rear parking brake shoes apart at the top enough to clear the shoe anchor and remove the parking brake shoes as an assembly from the disc brake adapter. 17. To remove the rear parking brake cable from the brake support plate on vehicles equipped with rear drum brakes: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4905 - Remove the parking brake cable from the parking brake actuating lever. - Remove the actuating spring between the brake shoe adjustment lever and the brake shoe. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4906 - Remove the parking brake cable from the rear brake support plate. The parking brake cable can be removed from brake support plate using a to inch box wrench to compress the locking fingers on the parking brake cable retainer. 18. To remove the rear parking brake cable from the disc brake adapter on vehicles equipped with rear disc brakes: - Remove the parking brake actuating lever from the parking brake cable. - Remove the parking brake cable from the rear disc brake adapter. The parking brake cable can be removed from the disc brake adapter using a to inch offset box wrench to compress the locking fingers on the parking brake cable retainer. 19. Remove the nuts, then the parking brake cable routing bracket from the tension strut mounting bolts. 20. Remove the parking brake cable and sealing grommet from floor pan of the vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. The procedure below applies to either of the two rear parking brake cables. 1. From underneath push the parking brake cable through the hole in the floor pan of the vehicle making sure the cable sealing grommet is installed in the floor pan as far as possible to insure a good seal. 2. Attach the parking brake cable routing bracket to the tension strut mounting bolts. Install and tighten the mounting nuts to a torque of 28 Nm (250 in. lbs.). 3. Install the parking brake cable into the brake support plate or the rear disc brake adapter. Be sure the locking fingers on the cable retainer are expanded once the cable is pushed all the way into the support plate or brake adapter hole to ensure the cable is securely held in place. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4907 4. On vehicles equipped with rear drum brakes: - Install the parking brake cable on the parking brake cable actuating lever. - Install the actuating spring to the brake shoe and the brake adjustment lever. 5. On vehicles equipped with rear disc brakes: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4908 - Install the parking brake shoes actuator lever on the parking brake cable. - Install the parking brake shoe assemblies on the disc brake adapter. 6. Install the hub and bearing on the rear spindle. Install a new hub and bearing retaining nut. Tighten the retaining nut to a torque of 217 Nm (160 ft. lbs.). 7. Install the hub and bearing dust cap. 8. On drum brake equipped vehicles, install the rear brake drum. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4909 9. On vehicles equipped with rear disc brakes, install the brake rotor, then the disc brake caliper. Install the two caliper guide pin bolts, then tighten them to a torque of 22 Nm (192 in. lbs.). 10. Install the rear tire and wheel assembly. Tighten all wheel nuts to a torque of 135 Nm (100 ft. lbs.). 11. Lower the vehicle. 12. Ensure that the seal grommet on the cable that was installed from underneath is fully seated into the floor pan. 13. Route the parking brake cable under the carpeting, up to parking brake cable retaining bracket on floor pan. Install the parking brake cable through the retaining bracket. Push the cable in until the locking fingers on the cable retainer lock the cable into place. 14. Install the rear parking brake cables into the equalizer on the parking brake lever output cable. 15. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever. NOTE: The parking brake lever can be in any position when releasing the automatic adjuster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 4910 16. Keeping your hands clear of the automatic adjuster sector and pawl area, firmly grasp the parking brake lever pin punch (or locking pin if a new mechanism has been installed), then quickly remove it from the parking brake lever mechanism. This will allow the park brake lever mechanism to automatically adjust the parking brake cables. 17. Cycle the parking brake lever once to position the parking brake cables, then return the parking brake lever its released position. 18. Check the rear wheels of the vehicle. They should rotate freely without dragging with the lever in its released position. 19. Reposition the rear carpeting into place. 20. Install the rear seat cushion. Be sure the seat cushion is fully installed in the retainers on the floor pan of the vehicle. 21. Fully apply the parking brake lever. 22. Install the center console and its mounting screws. 23. Remove the blocks from the tires and wheels. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking Brake Lever Mounting Nut And Screw .................................................................................................................................... 28 Nm (250 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4914 Parking Brake Lever: Service and Repair PARKING BRAKE LEVER REMOVAL WARNING: - THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 25 POUNDS. DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE. KEEP HANDS OUT OF AUTOMATIC ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. - WHEN REPAIRS TO THE PARKING BRAKE LEVER OR CABLES ARE REQUIRED, THE AUTOMATIC ADJUSTER MUST BE LOADED AND LOCKED OUT TO AVOID POSSIBLE INJURY. THE LEVER ADJUSTMENT MECHANISM CAN BE LOADED AND LOCKED OUT AS OUTLINED IN THIS PROCEDURE. 1. Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released. 2. Fully apply the parking brake lever, then shift the transmission into neutral. 3. Remove the screws attaching the center console, then remove the center console. 4. Lower the parking brake lever handle to the released position. 5. Grasp the parking brake lever output cable by hand and pull upward. Continue pulling on the cable until a pin punch can be inserted through the hole in the lever mechanism sector gear and the hole in the right side of its mounting bracket . This will lock the parking brake automatic adjustment mechanism in place and take tension off the parking brake cables. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4915 6. Remove both rear parking brake cables from the parking brake cable equalizer. 7. Remove the wiring harness electrical connector from the parking brake warning lamp switch on the parking brake lever. 8. Remove the two nuts attaching the parking brake lever to the vehicle. 9. Remove the parking brake lever from the vehicle. INSTALLATION WARNING: THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 25 POUNDS. DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE. KEEP HANDS OUT OF AUTOMATIC ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4916 1. Place the parking brake lever on the mounting studs on the vehicle floor. Install and tighten the two mounting nuts to a torque of 28 Nm (250 in. lbs.). 2. Connect the wiring harness electrical connector on the parking brake warning lamp switch. 3. Install both rear park brake cables into the equalizer on the parking brake lever output cable. 4. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever. NOTE: The parking brake lever can only be in the released position when releasing the automatic adjuster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4917 5. Keeping your hands clear of the automatic adjuster sector and pawl area, firmly grasp the parking brake lever pin punch (or locking pin if a new mechanism has been installed), then quickly remove it from the parking brake lever mechanism. This will allow the park brake lever mechanism to automatically adjust the parking brake cables. 6. Cycle the parking brake lever once to position the parking brake cables, then return the parking brake lever its released position. 7. Check the rear wheels of the vehicle. They should rotate freely without dragging with the lever in its released position. 8. Fully apply the parking brake lever. 9. Install the center console and its mounting screws. 10. Remove the blocks from the tires and wheels. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments ADJUSTMENT NOTE: The parking brake shoes used in the drum in-hat park brake system do not automatically adjust to compensate for brake shoe lining wear. Therefore, it is necessary to manually adjust the parking brake shoes. 1. Verify the parking brake lever is in the released position. 2. Raise the vehicle. 3. Remove the rubber plug from the adjusting hole in the disc brake caliper adapter. 4. Adjust the parking brakes. Use the first bullet point for the adjustment of the left side parking brake shoes. Use the second bullet point for the adjustment of the right side parking brake shoes. Insert a medium size screwdriver through adjustment hole in the left backing plate. Position the screwdriver against the star wheel on the parking brake shoe adjuster. Using the screwdriver, rotate the star wheel downward until a slight drag is noticed when turning the rear tire and wheel assembly. Then, using the screwdriver, slowly rotate the star wheel upward, backing off the adjuster, just enough to allow the rear tire and wheel assembly to rotate without the parking brake shoes dragging. Do not back off the adjuster star wheel more than two clicks past the point of no drag. The parking brake shoe-to-drum clearance is now properly set. - Insert a medium size screwdriver through adjustment hole in the right backing plate. Position the screwdriver against the star wheel on the parking brake shoe adjuster. Using the screwdriver, rotate the star wheel upward until a slight drag is noticed when turning the rear tire and wheel assembly. Then, using the screwdriver, slowly rotate the star wheel downward, backing off the adjuster, just enough to allow the rear tire and wheel assembly to rotate without the parking brake shoes dragging. Do not back off the adjuster star wheel more that two clicks past the point of no drag. The parking brake shoe-to-drum clearance is now properly set. 5. Install the rubber plug in the adjusting holes of the disc brake caliper adapter. 6. Lower the vehicle until the rear tires are just clearing the floor. 7. Reach inside the vehicle and fully apply and release the park brakes two times after adjusting the parking brake shoes. 8. With the parking brake lever in the fully applied position, attempt to hand rotate each rear tire and wheel assembly to ensure that the parking brake shoes are working. 9. With the parking brake lever in the released position, hand rotate each rear tire and wheel assembly to ensure that the parking brake shoes are not dragging. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4921 Parking Brake Shoe: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. NOTE: This procedure applies to vehicles with rear disc brakes only. 1. Raise the vehicle. 2. Remove the rear tire and wheel assembly. 3. Remove the rear disc brake caliper assembly from the brake rotor and store it out of the way. 4. Remove rear brake rotor. 5. Remove the dust cap from the rear hub and bearing. 6. Remove the rear hub and bearing assembly retaining nut and washer. 7. Remove the rear hub and bearing assembly from the rear spindle. 8. Remove the rear brake shoe assembly hold down clip. 9. Turn the brake shoe adjuster wheel until the adjuster is at shortest length. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4922 10. Remove the adjuster assembly from the parking brake shoe assemblies. 11. Remove the lower shoe-to-shoe spring. 12. Pull the rear brake shoe away from anchor. Remove the rear brake shoe and upper return spring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4923 13. Remove the front brake shoe hold-down clip. Remove the front brake shoe assembly. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. NOTE: This procedure applies to vehicles with rear disc brakes only. 1. Install the front brake shoe and secure it in place with a hold-down clip . 2. Install the rear brake shoe and the upper shoe return spring. Pull the rear brake shoe over the anchor block until it is properly located on the adapter. 3. Install the lower shoe-to-shoe return spring. 4. Install the brake shoe adjuster assembly with the star wheel towards the rear. 5. Install the rear brake shoe hold down clip. 6. Adjust the parking brake shoes to a diameter to 171.72 - 171.50 mm (6.75 - 6.75 inch). 7. Install the rear hub and bearing assembly on spindle. 8. Install a new hub and bearing assembly retaining nut. Tighten the retaining nut to a torque of 217 Nm (160 ft. lbs.). 9. Install the hub and bearing dust cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4924 10. Install the rear brake rotor. 11. Install rear disc brake caliper. 12. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 13. Repeat the above procedure to the parking brake shoes on the other side of the vehicle. 14. Adjust the parking brake shoes as necessary. 15. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4928 Fig. 27 Center Console - LHD Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power Brake Booster Mounting Nuts 34 Nm (25 ft. lbs.) Make/Type Bosch/Vacuum Mounting Studs M8 x 1.25 Diaphragm Size/Type 205 mm Tandem Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4933 Vacuum Brake Booster: Description and Operation DESCRIPTION There are two different power brake booster designs, although externally they appear the same. All vehicles use a 205 mm tandem diaphragm power brake booster. The two boosters are internally tuned differently depending on whether the vehicle is equipped with the standard front disc/rear drum brake combination or the optional front disc/rear disc (four-wheel disc) brake combination. 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 brake booster, the date it was built and who manufactured it. The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop the 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. As the brake pedal is depressed, the power booster input rod moves forward. This opens and closes valves in the power brake 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, hydraulic pressure is created in the brake system. The power brake vacuum booster assembly mounts on the engine side of the dash panel. The booster input push rod connects to the brake pedal. A vacuum line connects the power booster to the intake manifold. The master cylinder is bolted to the front of the power brake booster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4934 Vacuum Brake Booster: Testing and Inspection DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER BASIC TEST 1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose on the side of the vacuum check valve that leads to the speed control, then connect a vacuum gauge to the open vacuum port on the valve. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches, the hose or check to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST 1. Disconnect the vacuum hose on the side of the power brake booster vacuum check valve that leads to the speed control, then connect a vacuum gauge to the open vacuum port on the valve. 2. Remove the remaining hose on the vacuum check valve that is not the vacuum supply hose coming from the intake manifold. Cap off the open port on the check valve. 3. Start the engine. 4. Allow the engine to warm up to normal operating temperature and engine idle. 5. Using vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test. 6. Remove the pliers from the hose temporarily. 7. Apply light effort (approximately 15 lbs. of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 8. Have an assistant reattach the pliers to the vacuum supply hose. 9. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) Vacuum Brake Booster: Service and Repair Removal and Installation (Left Hand Drive) REMOVAL - LHD NOTE: Before proceeding, Refer to Service Precautions. 1. Disconnect negative (ground) cable from the battery and isolate the cable. 2. Disconnect the positive cable from the battery, then remove the battery from the battery tray. There is one nut securing the clamp on the backside of the battery holding it in place. 3. Remove the one nut and one bolt securing the air cleaner box in place, then disconnect the wiring harness connector at the air inlet sensor. 4. Lift the air cleaner box upward enough to clear its grommeted alignment post, then move the air cleaner box forward just enough to access the battery tray mounting bolts. 5. Remove the 2 bolts, then the 2 nuts mounting the battery tray to its bracket. Remove the battery tray. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal 4-5 times while the engine is not running until a firm brake pedal is achieved. 6. Remove the master cylinder. 7. If the vehicle is equipped with ABS, remove the Integrated Control Unit (ICU). 8. If the vehicle is equipped with ABS, remove the three bolts securing the ICU mounting bracket to the frame rail. 9. Disconnect the vacuum hoses from the check valve on the power brake booster, but do not remove the check valve from Dower brake booster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) > Page 4937 10. Locate the brake pedal-to-power brake booster input rod attachment under the instrument panel. Position a small screwdriver under the center tang of the retaining clip. Rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin. Remove the clip. CAUTION: Discard the used retaining clip, it is not to be reused. Replace the clip with a new one on reassembly. 11. Remove the four nuts attaching the power brake booster to the instrument panel. The nuts are accessible from under the instrument panel in the area of the brake pedal bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) > Page 4938 12. Slide the power brake booster forward until mounting studs clear the instrument panel. Turn the booster sideways, then remove it from the vehicle. INSTALLATION - LHD 1. Turn the power brake booster sideways, then install it into the engine compartment down past the heater hoses and the strut tower. Rotate the booster so its four mounting studs and input rod are pointed straight toward the instrument panel. Slide the input rod and studs through the instrument panel and into mounting position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) > Page 4939 2. Under the instrument panel, install the four power brake booster mounting nuts. Tighten the nuts to a torque of 34 Nm (25 ft. lbs.). 3. Using lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the brake booster input rod. CAUTION: Use only a new brake booster input rod to-brake pedal retaining clip to ensure proper retainment. - Install a new brake lamp switch anytime the old switch is removed, the brake booster or pedals have been changed or removed. 4. Connect the power brake booster input rod-to brake pedal pin. Install a new retaining clip. Do not use the old clip. 5. Install and adjust a new brake lamp switch. 6. Connect all previously removed vacuum hoses to the vacuum check valve. 7. If the vehicle is equipped with ABS, install the ICU mounting bracket on the frame rail using its three bolts. Tighten the nuts to a torque of 23 Nm (200 in. lbs.). 8. If the vehicle is equipped with ABS, reinstall the ICU. 9. Install the master cylinder. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) > Page 4940 10. Position the battery tray back in place. Install the two bolts, then the two nuts mounting the battery tray to its bracket. Tighten the two bolts and nuts to a torque of 34 Nm (25 ft. lbs.) 11. Reinstall the air cleaner box onto its grommeted alignment post. 12. Install the one nut and one bolt securing the air cleaner box in place, then connect the wiring harness connector at the air inlet sensor. 13. Install the battery and clamp it in place. 14. Connect the positive, then the negative (ground) cable on the battery. 15. Bleed the base brake system. 16. Road test the vehicle to ensure proper operation of the brakes. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) > Page 4941 Vacuum Brake Booster: Service and Repair Removal and Installation (Right Hand Drive) REMOVAL - RHD 1. Disconnect and isolate the negative battery cable. CAUTION: Pump the brake pedal several times to relieve the vacuum in the power brake booster. This will prevent the booster from sucking in any contamination when the master cylinder is removed. 2. Remove the master cylinder from the vehicle. 3. Remove the air cleaner assembly. 4. Remove the battery and battery tray from the vehicle. 5. Remove the heater core coolant supply tube support bracket bolts. 6. Remove the (2) coolant reservoir retaining bolts from the dash panel. Disconnect the coolant overflow hose from the thermostat housing and remove the coolant reservoir from the dash panel. 7. Working from underneath the instrument panel, disconnect the brake pedal push rod. Remove the retaining clip from the end of the brake pedal mounted stud, then slide the push rod straight off the pin. 8. If equipped, disconnect the clutch pedal push rod. Depress the plastic retention clip on the end of the clutch pedal mounted stud, while sliding the push rod straight off the stud. 9. Rotate the clutch master cylinder to line up the square shaped retaining boss with the square shaped opening in the brake pedal support bracket. 10. Remove the (4) brake booster retaining nuts. 11. Working from inside the engine compartment, remove the (2) clutch fluid reservoir retaining bolts from the dash panel. 12. Remove the clutch master cylinder from the dash panel by pulling it straight out. Position the reservoir and line assembly out of the way. 13. Remove the brake booster from the dash panel by pulling it straight out, then rotate the booster and slide it between the engine and the dash panel towards the battery tray. Slide the booster under the heater core coolant supply hoses and out of the engine bay. INSTALLATION - RHD 1. Position the brake booster on the dash panel by reversing the path taken to remove the booster. Slide the booster under the plenum on the battery tray side of the engine compartment. Slide the booster between the engine and dash panel until it can be installed on the right side of the dash panel. 2. Reinstall the vacuum supply hose on the booster check valve. Make sure the booster check valve is firmly seated in the rubber grommet and did not become dislodged during the booster installation. 3. If equipped, install the clutch master cylinder through the dash panel. 4. Install the clutch fluid reservoir. Torque the retaining bolts to 7 Nm (62 in. lbs.). 5. Working from underneath the instrument panel, install the four brake booster retaining nuts. Torque the nuts to 34 Nm (25 ft. lbs.). 6. Grease the brake pedal pin and slide the brake booster push rod onto the pedal pin. Install the retaining clip. 7. If equipped, lock the clutch master cylinder in position. Rotate the clutch master cylinder to line up the square shaped retaining boss with the square shaped opening in the brake pedal support bracket. Once the cylinder is inserted through the brake pedal support bracket rotate 90° to lock it in position. 8. Connect the clutch pedal push rod. Slide the push rod on the clutch pedal mounted stud until the plastic retention clip locks it in place. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation (Left Hand Drive) > Page 4942 9. Install the coolant reservoir. Torque the retaining bolts to 7 Nm (62 in. lbs.). Connect the coolant overflow hose on the thermostat housing. 10. Install the heater core coolant supply tube support bracket bolts. Torque the bolts to 36 Nm (27 ft. lbs.). 11. Install the battery and battery tray in the vehicle. 12. Install the air cleaner assembly. 13. Install the master cylinder on the vehicle. 14. Fill the brake fluid reservoir to specification. 15. Bleed the air from the brake hydraulic system. WARNING: Be certain a firm brake pedal is achieved before attempting to move the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig.1 Integrated Control Unit (ICU) The CAB is mounted to the ICU as part of the Integrated Control Unit (ICU). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4947 Controller Antilock Brake Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4948 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. Fig.3 CAB Mounting 3. Disconnect pump/motor connector from CAB. 4. Remove four screws securing CAB to HCU half of ICU. Remove CAB from HCU. 5. Pull outward on CAB connector lock and disconnect 24-way wiring connector. Remove CAB from vehicle. INSTALLATION 1. Connect 24-way wiring connector to CAB and push in connector lock. 2. Align CAB with HCU half of ICU, then slide CAB up over HCU valves. Install four CAB mounting screws. Tighten mounting screws to 2 Nm (17 in. lbs.) torque. 3. Connect pump/motor connector. 4. Lower vehicle. 5. Connect battery negative cable. 6. Connect DRBIII to vehicle to initialize system. Check and clear any faults. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4953 Fig. 37 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4954 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4955 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4956 Brake Fluid Level Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4957 Brake Fluid Level Sensor/Switch: Service Precautions CAUTION: An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system. The entire brake hydraulic system should be checked for evidence of a leak. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4958 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch is located in the left side of the brake fluid reservoir on the master cylinder. It is clipped into the reservoir. It can be removed from the reservoir and replaced if necessary. OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder reservoir has dropped below an acceptable level. As the fluid drops below the designed level, the fluid level switch closes and grounds the red BRAKE warning indicator circuit. This turns on the red BRAKE warning indicator. At this time, the master cylinder brake fluid reservoir must be checked and filled to the full mark with DOT 3 brake fluid. Check the entire brake hydraulic system for evidence of a leak. CAUTION: An abnormal loss of brake fluid in the master cylinder fluid reservoir could be caused by a leak in the hydraulic system. The entire brake hydraulic system should be checked for evidence of a leak. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4959 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir. 2. Push together the retaining tabs holding the brake fluid level switch in place in the brake fluid reservoir. 3. Pull the brake fluid level switch out the other side of the reservoir. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Align the brake fluid level switch with its mounting hole on the left side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs are expanded on the other side of the reservoir, locking it in place. 2. Connect the brake fluid level switch wiring connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4963 Fig. 27 Center Console - LHD Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications TORQUE SPECIFICATIONS ABS Wheel Speed Sensor Mounting Screw ...................................................................................................................................... 12 Nm (105 in. lbs.) WHEEL SPEED SENSOR AIR GAP Front Sensor ........................................................................................................................................ ......................... 0.28 - 1.42 mm (0.011 - 0.056 in.) Rear Sensor ........................................................ .......................................................................................................... 0.45 - 1.12 mm (0.018 - 0.044 in.) TONE WHEEL RUNOUT Front .................................................................................................................................................... ................................................................. 0.009 in. Rear .................................................................... .................................................................................................................................................. 0.009 in. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations TONE WHEELS FRONT REAR WHEEL SPEED SENSORS FRONT Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4969 REAR Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4970 Wheel Speed Sensor: Connector Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4971 Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4972 Fig. 5 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4973 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4974 Fig. 37 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4975 Fig. 38 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4976 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4977 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4978 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Right Rear Wheel Speed Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel Wheel Speed Sensor: Description and Operation Tone Wheel TONE WHEEL DESCRIPTION The tone wheel is used in conjunction with the wheel speed sensors. OPERATION The tone wheel is used in conjunction with the wheel speed sensors. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4981 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor Front FRONT WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A wheel speed sensor is used at each wheel. The gear (tooth) type tone wheel serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one tone wheel. The front wheel speed sensors are attached to bosses in the steering knuckle. The tone wheel is an integral part of the outboard constant velocity joint located in the front axle shaft. WSS air gaps are not adjustable. The initial factory WSS air gap specification can be found in SPECIFICATIONS. Each WSS is serviced individually. The tone wheels are serviced as Dart of the drive shaft. OPERATION The CAB sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the CAB. The Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4982 relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the CAB, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the CAB. When a valley of the tone wheel is aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the CAB. As the tone wheel rotates, the tooth shifts the magnetic field and the IC enables a second 7 mA current source. The CAB senses a voltage signal of approximately 1.6 volts and 14 mA. The CAB measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABS CAB as the wheel speed. Rear REAR WHEEL SPEED SENSOR DESCRIPTION The Mark 20e system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A wheel speed sensor is used at each wheel. The gear (tooth) type tone wheel serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one tone wheel. The rear wheel speed sensors are mounted through the disc brake adapter. The rear tone wheels are mounted to and rotate with the hub and bearing assemblies. The WSS air gaps are not adjustable. The initial factory WSS air gap specification can be found in SPECIFICATIONS. Each WSS is serviced Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Tone Wheel > Page 4983 individually. The tone wheels are serviced as an assembly with the hub and bearing assemblies. OPERATION The CAB sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the CAB. The relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the CAB, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the CAB. When a valley of the tone wheel is aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the CAB. As the tone wheel rotates, the tooth shifts the magnetic field and the IC enables a second 7 mA current source. The CAB senses a voltage signal of approximately 1.6 volts and 14 mA. The CAB measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABS CAB as the wheel speed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 4984 Wheel Speed Sensor: Testing and Inspection TONE WHEEL INSPECTION Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes: missing, chipped, or broken teeth - contact with the wheel speed sensor - wheel speed sensor to tone wheel alignment - wheel speed sensor to tone wheel clearance - excessive tone wheel runout - tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement, the rear hub and bearing must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive tone wheel runout can cause erratic wheel speed sensor signals. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replace the front driveshaft or rear hub and bearing as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Raise the vehicle. 2. Disconnect the wheel speed sensor cable connector from the wiring harness on the inside of the frame rail above the front suspension crossmember. The connector has a locking tab which that must be pulled back before the connector release tang can be depressed, releasing the connection. 3. If the sensor being removed is a left front, unclip the speed sensor cable from the brake tube on the inside of and under the frame rail. 4. Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4987 5. Remove the bolt mounting the wheel speed sensor head to the steering knuckle. CAUTION: When removing a wheel speed sensor from the knuckle, do not use pliers on the sensor head. This may damage the sensor head. If the sensor has seized, use a hammer and a punch to tap the edge of the sensor head ear, rocking the sensor side-to-side until free. 6. Carefully, remove the sensor head from the steering knuckle. 7. Remove the screw securing the wheel speed sensor to the rear of the strut. Remove the wheel speed sensor. INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Attach the wheel speed sensor to the strut using the its mounting screw. 2. Install the wheel speed sensor head in the steering knuckle. Install the mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. From the sensor bracket on the strut, loop the sensor cable upward, then downward at the outside of the frame rail. Install the speed sensor cable grommet onto the retaining bracket attached to the brake hose on the outside of the frame rail. 4. Loop the wheel speed sensor cable around the bottom of the frame rail and connect it to the wiring harness connector on the inside of the frame rail. Remember to push in the locking tab on the connector. 5. If the sensor being installed is the left front, clip the speed sensor cable to the brake tube on the inside of and under the frame rail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4988 6. Lower the vehicle. 7. Road test vehicle to ensure proper operation of the base brakes and ABS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4989 Wheel Speed Sensor: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to WARNING. 1. Raise the vehicle. 2. Disconnect the wheel speed sensor cable connector from the vehicle wiring harness. Remove the clip attaching wheel speed sensor cable connector to the vehicle's body. 3. Remove the wheel 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. 4. Remove the bolt attaching the wheel speed sensor cable routing bracket to rear strut. CAUTION: When removing a wheel speed sensor from the rear disc brake adapter, do not use pliers on the sensor head. This may damage the sensor head. If the sensor has seized, use a hammer and a punch to tap the edge of the sensor head ear, rocking the sensor side-to-side until free. 5. Remove the bolt attaching the wheel speed sensor to the rear disc brake adapter, then carefully remove the sensor head from the rear disc brake Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4990 adapter and vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to WARNING. CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head into the disc brake adapter. 2. Install the wheel speed sensor mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. Install the wheel speed sensor cable routing bracket on the rear strut. 4. Install wheel speed sensor cable into the routing clips on the rear brake hose and brake tube. 5. Connect the wheel speed sensor cable connector into vehicle wiring harness. Install the clip attaching the wheel speed sensor cable connector to vehicle's body. 6. Lower the vehicle. 7. Road test the vehicle to ensure proper operation of the base brakes and ABS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4997 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4998 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4999 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5000 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations > Page 5005 Clutch Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations > Page 5006 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component Locations > Page 5007 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5008 Clutch Interlock/Upstop Switch (MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5009 Clutch Switch: Description and Operation CLUTCH INTERLOCK/UPSTOP SWITCH DESCRIPTION - LHD The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 13). The switch assembly is located in the clutch/brake pedal bracket assembly (Fig. 14), each switch being fastened by four plastic wing tabs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5010 DESCRIPTION - RHD The RHD clutch interlock/upstop switch (Fig. 15) consists of a single, multi-function switch that is activated by hydraulic clutch master cylinder push rod travel. OPERATION - CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch pedal in the up position (not depressed), or under normal conditions with the clutch engaged and the transaxle in gear. WARNING: WHEN THERE IS A LOSS OF CLUTCH SYSTEM HYDRAULIC FLUID, OR THE CLUTCH MASTER CYLINDER PUSHROD IS DISCONNECTED FROM THE PEDAL LEVER, THE ENGINE MAY START WITH THE CLUTCH ENGAGED, CAUSING UNDESIRABLE VEHICLE MOVEMENT IF THE TRANSAXLE IS IN ANY GEAR. The switch is open while the clutch pedal is at rest or in the up position. When the clutch pedal is fully depressed on LHD models, the clutch pedal lever closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. When the clutch pedal is fully depressed on RHD models, the master cylinder push rod closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. The interlock switch is not adjustable. OPERATION - CLUTCH PEDAL UPSTOP SWITCH With the clutch pedal at rest, the clutch pedal upstop switch is closed, allowing speed control operation. When the clutch pedal is depressed, the upstop switch opens and signals the PCM to cancel speed control operation, and enter a modified engine calibration schedule to improve driveability during gear-to-gear shifts. The upstop switch is not adjustable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis Clutch Switch: Testing and Inspection Service Diagnosis SERVICE DIAGNOSIS - CLUTCH INTERLOCK/UPSTOP SWITCH The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 5013 The RHD clutch interlock/upstop switch (Fig. 17) consists of a single, multi-function switch that is activated by the hydraulic clutch master cylinder push rod. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 5014 Clutch Switch: Testing and Inspection Clutch Interlock Switch / Mechanical-Electrical Tests CLUTCH INTERLOCK SWITCH Mechanical Test 1. With the park brake set and the transaxle IN NEUTRAL, turn the ignition key to the start position. The engine starter should not crank with the clutch pedal at rest (not depressed). If the starter cranks, proceed to the electrical test to determine whether the switch is defective or the circuit is shorted. If the vehicle does not crank, proceed to the next step. 2. With the park brake set and the transaxle IN NEUTRAL, fully depress the clutch pedal and turn the ignition key to the start position. The engine starter should crank. If the starter does not crank, visually inspect the clutch pedal for obstructions (floor mat, etc.). Make sure the clutch pedal lever contacts and fully closes the switch on LHD applications, and for proper installation of the master cylinder push rod/bushing on the pedal pin on RHD applications. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 2 & 3 (Fig. 18) with the interlock switch not depressed (clutch pedal at rest). There should be no continuity between the terminals (open circuit). 5. LHD Models: Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm (0.050 inch) on LHD applications. The ohmmeter should show continuity (0 ohms resistance). RHD Models: Disconnect the push rod from the pedal pin and actuate the push rod by hand to close the switch. The ohmmeter should show continuity (0 ohms). Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked) it MUST be replaced before reinstalling the push rod to the pedal. 6. If ohmmeter readings do not fall within these ranges, the switch assembly, or the pedal bracket assembly, is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 5015 Clutch Switch: Testing and Inspection Upstop Switch / Mechanical-Electrical Tests UPSTOP SWITCH Mechanical Test 1. Raise vehicle on hoist. 2. Start engine and operate speed control to maintain speed. 3. Depress clutch pedal at least 33 mm (1.30 inch). Speed control operation should terminate. If speed control does not terminate, the upstop switch is defective or the related wiring is shorted. Proceed to the upstop switch electrical test. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 1 & 2 (Fig. 18) with the upstop switch depressed (clutch pedal at rest). The ohmmeter should show continuity (0 ohms). 5. Depress the clutch pedal at least 33 mm (1.30 inch) check for continuity between terminals 1 & 2. There should be no continuity between the terminals (open circuit). 6. If ohmmeter readings do not fall within these ranges, the switch assembly is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - LHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - LHD 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 19). 3. Disconnect upstop switch and brake lamp switch connectors. 4. Disconnect clutch master cylinder rod from clutch pedal pin. Inspect plastic retainer upon removal. If retainer is damaged, it MUST be replaced. 5. Remove brake booster push rod retaining clip from brake pedal. Disengage rod from pedal (Fig. 20). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 5018 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 21). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 21). 8. From under the hood, pull brake master cylinder/booster far enough forward to obtain pedal to bracket stud clearance. 9. Remove the pedal bracket assembly (Fig. 21). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 22) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION - LHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 5019 contacting pedals. 1. Install switches into the pedal bracket assembly as shown in (Fig. 22). Route harness as was prior to removal. Secure switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 42 Nm (31 ft. lbs.). 3. Install brake/clutch pedal bracket assembly into position. Install and tighten brake booster mounting nuts to 34 Nm (25 ft. lbs.). Install and tighten pedal bracket-to-instrument panel nuts to 34 Nm (25 ft. lbs.). 4. Install new stop lamp switch. 5. Connect brake booster rod to brake pedal. Install retainer clip (Fig. 20). 6. Loosen adjustment screw (Fig. 24). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 7. Connect clutch master cylinder pushrod. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.). 8. Connect interlock/upstop and stop lamp switch connectors. 9. Install left lower instrument panel bezel (Fig. 19). 10. Connect battery negative cable. 11. Verify proper switch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 5020 Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - RHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - RHD 1. Disconnect the master cylinder push rod from the pedal pin (Fig. 23). Inspect push rod retainer for damage. If it is damaged (broken/cracked), it must be replaced. 2. Squeeze together the tangs on the switch cover plate and slide the plate off the switch housing. 3. Disconnect the clutch interlock/upstop switch connector from the instrument panel wiring harness. 4. Remove the switch from the vehicle. INSTALLATION - RHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals. 1. Install the clutch interlock/upstop switch onto the master cylinder push rod, making sure that the push rod is oriented with the push rod retainer toward the wiring of the switch. The master cylinder push rod must be snapped into the clutch interlock/upstop switch along the smaller diameter of the push rod between the snap ring and the transition to the larger diameter. CAUTION: Improper assembly of the larger diameter of the push rod into the clutch interlock/upstop switch could cause damage to the switch or a clutch system failure. 2. Install the switch cover plate. CAUTION: Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked), it MUST be replaced. 3. Connect clutch master cylinder pushrod to the clutch pedal pin. 4. Route the wiring harness as it was prior to removal. 5. Secure the switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair "For information regarding this component please refer to steering column service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5029 Starter Relay: Diagrams Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5030 Starter Motor Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5031 Starter Relay: Description and Operation The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter solenoid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5032 Starter Relay: Service and Repair REMOVAL The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Technician Safety Information Jump Starting: Technician Safety Information WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Technician Safety Information > Page 5038 Jump Starting: Vehicle Damage Warnings CAUTION: - When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. - If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 5039 Jump Starting: Service and Repair STANDAD PROCEDURE - JUMP STARTING WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary - Frozen battery. - Yellow or bright color test indicator, if equipped. - Low battery fluid level. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn OFF all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn OFF all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. Fig. 6 Jumper Cable Clamp Connections 5. On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 6). 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 minutes), before cranking again. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 5040 Disconnect Cable Clamps As Follows: Disconnect BLACK cable clamp from engine ground on disabled vehicle. - When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal - Disconnect RED cable clamp from battery positive terminal on disabled vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation Battery Cable: Description and Operation The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of soft lead that is die cast onto one end of the battery cable wire. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some models. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. The battery positive cable terminal clamp is die cast onto the ends of two wires. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Power Distribution Center (PDC), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp is also die cast onto the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the right side of the engine cylinder block. The other wire has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw on the right front fender inner shield, near the battery. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5044 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. Voltage Drop Test The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: The battery is fully-charged and load tested. Refer to Standard Procedures for the proper battery charging and load test procedures. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned OFF. - To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay is located in the Power Distribution Center ( PDC), in the engine compartment. See the fuse and relay layout label affixed to the underside of the PDC cover for ASD relay identification and location. Fig.9 Test Battery Negative Connection Resistance - Typical 1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp (Fig. 9). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5045 Fig.10 Test Battery Positive Connection Resistance - Typical 2. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp (Fig. 10). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Fig.11 Test Battery Positive Cable Resistance - Typical 3. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Fig. 11). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5046 Fig.12 Test Ground Circuit Resistance - Typical 4. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 12). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5047 Battery Cable: Service and Repair REMOVAL 1. Turn the ignition switch to the OFF position. Be certain that all electrical accessories are turned OFF. 2. Disconnect and isolate the remote battery negative cable terminal. 3. Remove the battery from the vehicle. 4. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cables are free from the vehicle. 5. Remove the battery cables from the engine compartment. INSTALLATION 1. Position the battery cables in the engine compartment. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cables are installed exactly where they were in the vehicle. 3. Install the battery in the vehicle. 4. Connect the remote battery negative cable terminal. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig.1 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 5052 Battery Temperature Sensor: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 5053 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5054 Battery Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5055 Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air Temperature Sensor BATTERY TEMPERATURE SENSOR The IAT sensor attaches to the intake air duct (Fig. 1). The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor along with other stored parameters to determine values to use as an intake air temperature and a battery temperature. The IAT sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The battery temperature information along with data from monitored line voltage (B+), 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. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the single battery hold down retaining bolt. 3. Remove the battery hold down from the vehicle. INSTALLATION 1. Install the battery hold down in the vehicle. 2. Install the single battery hold down retaining bolt 3. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5060 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the vehicle. Fig.13 Battery Tray Removal 2. Remove two nuts to the rear and two bolts to the front of the battery tray (Fig. 13). 3. Remove the tray retaining bolt under the center of the tray. 4. Slide battery tray out form under the air cleaner assembly Do not remove the air cleaner assembly 5. Remove battery tray from vehicle. INSTALLATION 1. Slide battery tray in under the air cleaner assembly 2. Install two nuts at the rear and two bolts at the front of the battery tray. 3. Install the bolt located under the tray. 4. Install the battery in the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications TYPE ................................................................................................................................................... ................................................................ Mitsubishi PART NUMBER .................................................................................................................................. .............................................................. 4794222AC RATED SAE AMPS ............................................................................................................................. ................................................................... 85 amps MINIMUM TEST AMPS ....................................................................................................................... ................................................................. 75 amps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 5066 Alternator: Mechanical Specifications Generator Mounting Bolt ..................................................................................................................... ......................................................54 Nm (40 ft. lbs.) Generator Pivot Bolt ............................................................................................................................ ......................................................54 Nm (40 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Component Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Component Locations > Page 5069 Generator Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views Generator Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5072 Alternator: Description and 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. The generator produces DC voltage. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. 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 vehicles 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 - Damaged internal fins Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5073 Alternator: Service and Repair REMOVAL Fig.2 Battery Cable 1. Disconnect battery negative cable (Fig. 2). 2. Loosen the jam nut and adjustment bolt. 3. Raise vehicle and support. Fig.3 Splash Shield And Belt 4. Remove accessary drive splash shield (Fig. 3). 5. Loosen the lower mounting bolt. 6. Remove the generator drive belt. 7. Disconnect the generator field circuit wiring connector. Push the RED locking tab to release. 8. Remove the B+ terminal nut and wire. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5074 Fig.4 Lower Mounting Bolt 9. Remove the upper and lower mounting bolt (Fig. 4) and move generator off of pivot bracket. 10. Remove pivot bracket. Fig.5 Generator 11. Remove Generator (Fig. 5) through wheel well. INSTALLATION 1. Install generator (Fig. 5) through wheel well. 2. Install lower pivot bracket and tighten bolts to 54 Nm (40 ft. lbs.). 3. Loose install the upper and lower mounting bolts (Fig. 4). 4. Connect the generator field circuit wiring connector. Push the RED locking tab to lock. 5. Install the B+ terminal nut and wire. 6. Install the generator drive belt. 7. Lower vehicle. 8. Tension belt. Refer to the Cooling System for belt tension specification. 9. Tighten adjustment bolt. 10. Tighten the jam nut. 11. Raise vehicle and support. 12. Tighten lower mounting bolt and tighten bolts to 54 Nm (40 ft. lbs.). 13. Install splash shield (Fig. 3). 14. Lower vehicle. 15. Connect battery cable (Fig. 2). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and 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. 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 (B+) and calculated battery temperature or inlet air temperature sensor (refer to Battery Temperature Sensor or Inlet Air Temperature Sensor, if equipped, for more information ). It then determines a target charging voltage. If sensed battery voltage is lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is at the target voltage. A circuit in the PCM cycles the ground side of the generator field at 250 times per second (250Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Component Locations > Page 5083 Clutch Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Component Locations > Page 5084 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Component Locations > Page 5085 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5086 Clutch Interlock/Upstop Switch (MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5087 Clutch Switch: Description and Operation CLUTCH INTERLOCK/UPSTOP SWITCH DESCRIPTION - LHD The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 13). The switch assembly is located in the clutch/brake pedal bracket assembly (Fig. 14), each switch being fastened by four plastic wing tabs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5088 DESCRIPTION - RHD The RHD clutch interlock/upstop switch (Fig. 15) consists of a single, multi-function switch that is activated by hydraulic clutch master cylinder push rod travel. OPERATION - CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch pedal in the up position (not depressed), or under normal conditions with the clutch engaged and the transaxle in gear. WARNING: WHEN THERE IS A LOSS OF CLUTCH SYSTEM HYDRAULIC FLUID, OR THE CLUTCH MASTER CYLINDER PUSHROD IS DISCONNECTED FROM THE PEDAL LEVER, THE ENGINE MAY START WITH THE CLUTCH ENGAGED, CAUSING UNDESIRABLE VEHICLE MOVEMENT IF THE TRANSAXLE IS IN ANY GEAR. The switch is open while the clutch pedal is at rest or in the up position. When the clutch pedal is fully depressed on LHD models, the clutch pedal lever closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. When the clutch pedal is fully depressed on RHD models, the master cylinder push rod closes the switch, completing the signal circuit from the PCM and closing the ground path, allowing engine starter operation. The interlock switch is not adjustable. OPERATION - CLUTCH PEDAL UPSTOP SWITCH With the clutch pedal at rest, the clutch pedal upstop switch is closed, allowing speed control operation. When the clutch pedal is depressed, the upstop switch opens and signals the PCM to cancel speed control operation, and enter a modified engine calibration schedule to improve driveability during gear-to-gear shifts. The upstop switch is not adjustable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis Clutch Switch: Testing and Inspection Service Diagnosis SERVICE DIAGNOSIS - CLUTCH INTERLOCK/UPSTOP SWITCH The LHD clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 5091 The RHD clutch interlock/upstop switch (Fig. 17) consists of a single, multi-function switch that is activated by the hydraulic clutch master cylinder push rod. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 5092 Clutch Switch: Testing and Inspection Clutch Interlock Switch / Mechanical-Electrical Tests CLUTCH INTERLOCK SWITCH Mechanical Test 1. With the park brake set and the transaxle IN NEUTRAL, turn the ignition key to the start position. The engine starter should not crank with the clutch pedal at rest (not depressed). If the starter cranks, proceed to the electrical test to determine whether the switch is defective or the circuit is shorted. If the vehicle does not crank, proceed to the next step. 2. With the park brake set and the transaxle IN NEUTRAL, fully depress the clutch pedal and turn the ignition key to the start position. The engine starter should crank. If the starter does not crank, visually inspect the clutch pedal for obstructions (floor mat, etc.). Make sure the clutch pedal lever contacts and fully closes the switch on LHD applications, and for proper installation of the master cylinder push rod/bushing on the pedal pin on RHD applications. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 2 & 3 (Fig. 18) with the interlock switch not depressed (clutch pedal at rest). There should be no continuity between the terminals (open circuit). 5. LHD Models: Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm (0.050 inch) on LHD applications. The ohmmeter should show continuity (0 ohms resistance). RHD Models: Disconnect the push rod from the pedal pin and actuate the push rod by hand to close the switch. The ohmmeter should show continuity (0 ohms). Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked) it MUST be replaced before reinstalling the push rod to the pedal. 6. If ohmmeter readings do not fall within these ranges, the switch assembly, or the pedal bracket assembly, is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Service Diagnosis > Page 5093 Clutch Switch: Testing and Inspection Upstop Switch / Mechanical-Electrical Tests UPSTOP SWITCH Mechanical Test 1. Raise vehicle on hoist. 2. Start engine and operate speed control to maintain speed. 3. Depress clutch pedal at least 33 mm (1.30 inch). Speed control operation should terminate. If speed control does not terminate, the upstop switch is defective or the related wiring is shorted. Proceed to the upstop switch electrical test. Electrical Test 1. Move ignition key to the "OFF/LOCK" position and remove key. 2. Set park brake. 3. Disconnect the clutch interlock/upstop switch connector. 4. Using an ohmmeter, check for continuity between terminals 1 & 2 (Fig. 18) with the upstop switch depressed (clutch pedal at rest). The ohmmeter should show continuity (0 ohms). 5. Depress the clutch pedal at least 33 mm (1.30 inch) check for continuity between terminals 1 & 2. There should be no continuity between the terminals (open circuit). 6. If ohmmeter readings do not fall within these ranges, the switch assembly is defective and should be replaced. If the switch tests ok, wiring is defective. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - LHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - LHD 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 19). 3. Disconnect upstop switch and brake lamp switch connectors. 4. Disconnect clutch master cylinder rod from clutch pedal pin. Inspect plastic retainer upon removal. If retainer is damaged, it MUST be replaced. 5. Remove brake booster push rod retaining clip from brake pedal. Disengage rod from pedal (Fig. 20). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 5096 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 21). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 21). 8. From under the hood, pull brake master cylinder/booster far enough forward to obtain pedal to bracket stud clearance. 9. Remove the pedal bracket assembly (Fig. 21). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 22) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION - LHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 5097 contacting pedals. 1. Install switches into the pedal bracket assembly as shown in (Fig. 22). Route harness as was prior to removal. Secure switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 42 Nm (31 ft. lbs.). 3. Install brake/clutch pedal bracket assembly into position. Install and tighten brake booster mounting nuts to 34 Nm (25 ft. lbs.). Install and tighten pedal bracket-to-instrument panel nuts to 34 Nm (25 ft. lbs.). 4. Install new stop lamp switch. 5. Connect brake booster rod to brake pedal. Install retainer clip (Fig. 20). 6. Loosen adjustment screw (Fig. 24). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 7. Connect clutch master cylinder pushrod. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.). 8. Connect interlock/upstop and stop lamp switch connectors. 9. Install left lower instrument panel bezel (Fig. 19). 10. Connect battery negative cable. 11. Verify proper switch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Service and Repair > Clutch Interlock/Upstop Switch - LHD > Page 5098 Clutch Switch: Service and Repair Clutch Interlock/Upstop Switch - RHD CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL - RHD 1. Disconnect the master cylinder push rod from the pedal pin (Fig. 23). Inspect push rod retainer for damage. If it is damaged (broken/cracked), it must be replaced. 2. Squeeze together the tangs on the switch cover plate and slide the plate off the switch housing. 3. Disconnect the clutch interlock/upstop switch connector from the instrument panel wiring harness. 4. Remove the switch from the vehicle. INSTALLATION - RHD NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals. 1. Install the clutch interlock/upstop switch onto the master cylinder push rod, making sure that the push rod is oriented with the push rod retainer toward the wiring of the switch. The master cylinder push rod must be snapped into the clutch interlock/upstop switch along the smaller diameter of the push rod between the snap ring and the transition to the larger diameter. CAUTION: Improper assembly of the larger diameter of the push rod into the clutch interlock/upstop switch could cause damage to the switch or a clutch system failure. 2. Install the switch cover plate. CAUTION: Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked), it MUST be replaced. 3. Connect clutch master cylinder pushrod to the clutch pedal pin. 4. Route the wiring harness as it was prior to removal. 5. Secure the switch connector retaining push pin into the appropriate hole in the pedal bracket assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Application and ID Ignition Lock: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Ignition Lock ........................................................................................................................................ ................................................................... 161 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair "For information regarding this component please refer to steering column service and repair" Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Engine Application ............................................................................................................................... ............................................................ OHC - DOHC Power rating ..................................................... ........................................................................................................................................................... 1.1 Kw Voltage ................................................................................................................................................ ................................................................. 12 VOLTS Cranking Amperage Draw test ............................................................................................................ ......................................................... 150 - 280 Amps. NOTE: Engine should be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 5110 Starter Motor: Mechanical Specifications Engine Application ............................................................................................................................... ............................................................ OHC - DOHC No. of Fields ..................................................... .............................................................................................................................................................. ....... 6 No. of Poles .............................................................................................................................. ............................................................................................. 6 Brushes .............................................. .............................................................................................................................................................. ...................... 4 Drive .......................................................................................................................... ............................................................................ Planetary Gear Train NOTE: Engine should be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5111 Fig.9 Starter Mounting/Location Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5112 Starter Motor: Service Precautions CAUTION: It is critical that the alternator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5113 Starter Motor: Description and Operation The starter is a permanent magnet starter motor. The fields have six permanent magnets. A planetary gear train transmits power between starter motor and pinion shaft. The starter provides mechanical torque to rotate the crankshaft at an RPM (crank speed) necessary for self-sustained spark/ignition. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output Starter Motor: Service and Repair Starter Motor - High Output REMOVAL Fig.15 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 15). Fig.16 Air Cleaner Box 2. Disconnect the inlet hose from intake manifold and reposition the air cleaner box (Fig. 16). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5116 Fig.17 Starter Location 3. Starter location (Fig. 17). Fig.18 Starter Mounting/Location 4. Remove starter bolts (Fig. 18). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5117 Fig.19 Starter Electrical Connection 5. Remove starter assembly (Fig. 19). 6. Disengage latch and remove solenoid connector from starter assembly. Fig.20 Starter 7. Remove battery positive connector from starter assembly It is not necessary to remove the alternator output lead from the connector (Fig. 20). 8. Remove starter from vehicle. INSTALLATION 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Attach battery positive connector to starter. Ensure alternator output connector is snapped into the battery positive connector. Tighten the captive nut to 10 Nm (90 in. lbs.). CAUTION: It is critical that the alternator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Install solenoid connector to starter. Ensure that latch is fully engaged (Fig. 19). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5118 Fig.9 Starter Mounting/Location 4. Position the starter face into transmission housing. Start bottom mounting bolt and thread in until bolt is snug (Fig. 9). 5. Attach ground cable to upper starter mounting bolt. 6. Ensure the proper starter alignment before tightening the starter mounting bolts to 54 Nm (40 ft. lbs.) torque. 7. Reposition the air cleaner box into position and connect the inlet hose from intake manifold (Fig. 16). Fig.8 Battery Negative Cable Remove/Install 8. Connect negative battery cable (Fig. 8). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5119 Starter Motor: Service and Repair Starter Motor Replacement REMOVAL Fig.8 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 8). 2. Raise vehicle on hoist. Fig.9 Starter Mounting/Location 3. Remove starter bolts (Fig. 9). 4. Remove starter assembly. 5. Disengage latch and remove solenoid connector from starter assembly. 6. Remove battery positive connector from starter assembly. It is not necessary to remove the alternator output lead from the connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5120 INSTALLATION 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Attach battery positive connector to starter. Ensure alternator output connector is snapped into the battery positive connector. Tighten the captive nut to 10 Nm (90 in. lbs.). CAUTION: It is critical that the alternator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Install solenoid connector to starter. Ensure that latch is fully engaged. 4. Position the starter face into transmission housing. Start bottom mounting bolt and thread in until bolt is snug. 5. Attach ground cable to upper starter mounting bolt. 6. Ensure the proper starter alignment before tightening the starter mounting bolts to 54 Nm (40 ft. lbs.) torque. 7. Lower vehicle 8. Connect negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5121 Starter Motor: Service and Repair With Automatic Transmission Starter Motor - 4 Speed Auto Replacement REMOVAL Automatic Transmission 1. Disconnect the negative battery cable. 2. Remove the air cleaner box, refer to the air cleaner box removal/installation. Fig.21 Intake Support Bracket 3. Remove the 2 upper bracket bolts for the intake support (Fig. 21). 4. Raise vehicle and support. Fig.22 Oil Pan Bracket 5. Remove the oil pan support bracket (Fig. 22). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 5122 Fig.23 Intake Support Bracket Lower Bolts 6. Remove the intake support bracket (Fig. 23). 7. Disconnect the battery cable and solenoid connection from the starter. 8. Remove the starter bolts. 9. Remove starter. INSTALLATION Automatic Transmission 1. Install starter. 2. Install the starter bolts. 3. Connect the battery cable and solenoid connection from the starter. 4. Install the intake support bracket (Fig. 23). 5. Install the oil pan support bracket (Fig. 22). 6. Lower vehicle. 7. Install the 2 upper bracket bolts for the intake support (Fig. 21). 8. Install the air cleaner box, refer to the air cleaner box removal/installation. 9. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5126 Starter Relay: Diagrams Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5127 Starter Motor Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5128 Starter Relay: Description and Operation The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter solenoid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5129 Starter Relay: Service and Repair REMOVAL The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Battery Nut ................................................................................................................ ......................................................10 Nm (90 in. lbs) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 5133 Starter Solenoid: Locations The Starter Solenoid is mounted directly to the Starter Motor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 5134 Starter Solenoid: Description and Operation The Starter Solenoid is mounted directly to the Starter Motor. The Starter Solenoid is a switching device used to activate the high amperage starter motor circuit from a low amperage control circuit. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Fig. 12 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 Cigar Lighter/Power Outlet Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5166 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.1 Cigar Lighter/Power Outlet Base Removal 2. Look inside and note position of the retaining bosses (Fig. 1). 3. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. Fig.2 Cigar Lighter/Power Outlet Base Removal 4. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the same (Fig. 2). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5167 3. Push base into the bezel till it locks. 4. Install cigar lighter cap and check operation of element. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-11-2 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5171 8w-11-3 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5172 Circuit Breakers Circuit Breakers Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5173 Circuit Breaker: Diagrams Circuit Breakers - LHD Circuit Breakers - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set Diode: Customer Interest Restraint System - Erroneous Airbag DTC Set NUMBER: 08-013-03 GROUP: Electrical DATE: May 16, 2003 SUBJECT: Erroneous Airbag Diagnostic Trouble Code (DTC) - Loss of Ignition Run/Start NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves adding a diode to the L4 circuit. MODELS: 2003 (PL) Neon/SX 2.0 NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH DAYTIME RUNNING LAMPS (DRL) (SALES CODE LMN). SYMPTOM/CONDITION: Vehicle sets DTC "Loss of Ignition Run/Start". NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED FROM THE RUN POSITION TO THE OFF POSITION WHILE THE HEADLAMPS REMAIN ON. A VOLTAGE SPIKE FROM THE DAYTIME RUNNING LAMPS COULD OCCUR SETTING THE DTC. DIAGNOSIS: Using the Diagnostic Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present1 other than listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC listed above is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Open the driver's door. Remove the left instrument panel end cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5182 3. Remove the 2 fuse block mounting screws holding the fuse block to the bracket (Fig. 1). 4. Pull the fuse block and wiring harness out the instrument panel end cap opening. 5. Unwrap the wiring harness covering up to the point that the harness exits the instrument panel. 6. Locate the L4 VT/WT wire in the wiring harness going toward the instrument panel. (Fig. 2). 7. Cut the wire approximately 101.6 mm (4 in.) from the fuse block terminal. 8. Slide the heat shrink tubing over the wire and slide the tubing up the wire out of the way until needed in step 10. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5183 9. Splice in the diode kit (p/n 05107069AA) following procedures outlined in the TechCONNECT/MDS2 or 2003 Neon/SX 2.0 service manual (Publication No. 81-270-03028) page 8W-01-14 and 15 (Fig. 3). NOTE: THE DIODE IS TO BE INSTALLED WITH THE STRIPPED END AWAY FROM THE FUSE BLOCK. 10. Once the diode is soldered in place, slide the heat shrink tubing over the diode and shrink the tubing to seal the diode from the elements. 11. Install the covering on the wiring harness (Fig. 4). Apply electrical tape around the covering in a couple of places to secure. 12. Install the fuse block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5184 13. Install the 2 fuse block mounting screws. 14. Install instrument panel left end cap. 15. Install battery negative terminal. 16. Cycle the ignition switch from the RUN position to the OFF position while the headlamps are on. 17. Check DTC's in the airbag control module. 18. If the DTC does not return proceed to step 19. If the "Loss of Ignition Run/Start" DTC returns, check the installation of the diode. Be sure the stripped end of the diode is facing away from the fuse block. Repeat steps 11 through 18. NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK TO THE CORRECT TIME WHEN THE PROCEDURE IS COMPLETE. 19. Erase DTC's. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System Erroneous Airbag DTC Set Diode: All Technical Service Bulletins Restraint System - Erroneous Airbag DTC Set NUMBER: 08-013-03 GROUP: Electrical DATE: May 16, 2003 SUBJECT: Erroneous Airbag Diagnostic Trouble Code (DTC) - Loss of Ignition Run/Start NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves adding a diode to the L4 circuit. MODELS: 2003 (PL) Neon/SX 2.0 NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH DAYTIME RUNNING LAMPS (DRL) (SALES CODE LMN). SYMPTOM/CONDITION: Vehicle sets DTC "Loss of Ignition Run/Start". NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED FROM THE RUN POSITION TO THE OFF POSITION WHILE THE HEADLAMPS REMAIN ON. A VOLTAGE SPIKE FROM THE DAYTIME RUNNING LAMPS COULD OCCUR SETTING THE DTC. DIAGNOSIS: Using the Diagnostic Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present1 other than listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC listed above is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Open the driver's door. Remove the left instrument panel end cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System Erroneous Airbag DTC Set > Page 5190 3. Remove the 2 fuse block mounting screws holding the fuse block to the bracket (Fig. 1). 4. Pull the fuse block and wiring harness out the instrument panel end cap opening. 5. Unwrap the wiring harness covering up to the point that the harness exits the instrument panel. 6. Locate the L4 VT/WT wire in the wiring harness going toward the instrument panel. (Fig. 2). 7. Cut the wire approximately 101.6 mm (4 in.) from the fuse block terminal. 8. Slide the heat shrink tubing over the wire and slide the tubing up the wire out of the way until needed in step 10. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System Erroneous Airbag DTC Set > Page 5191 9. Splice in the diode kit (p/n 05107069AA) following procedures outlined in the TechCONNECT/MDS2 or 2003 Neon/SX 2.0 service manual (Publication No. 81-270-03028) page 8W-01-14 and 15 (Fig. 3). NOTE: THE DIODE IS TO BE INSTALLED WITH THE STRIPPED END AWAY FROM THE FUSE BLOCK. 10. Once the diode is soldered in place, slide the heat shrink tubing over the diode and shrink the tubing to seal the diode from the elements. 11. Install the covering on the wiring harness (Fig. 4). Apply electrical tape around the covering in a couple of places to secure. 12. Install the fuse block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System Erroneous Airbag DTC Set > Page 5192 13. Install the 2 fuse block mounting screws. 14. Install instrument panel left end cap. 15. Install battery negative terminal. 16. Cycle the ignition switch from the RUN position to the OFF position while the headlamps are on. 17. Check DTC's in the airbag control module. 18. If the DTC does not return proceed to step 19. If the "Loss of Ignition Run/Start" DTC returns, check the installation of the diode. Be sure the stripped end of the diode is facing away from the fuse block. Repeat steps 11 through 18. NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK TO THE CORRECT TIME WHEN THE PROCEDURE IS COMPLETE. 19. Erase DTC's. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations 1.6L and 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5196 Power Distribution Center (PDC): Application and ID Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5197 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5198 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5199 8w-10-5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5200 8w-10-6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5201 8w-10-7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5202 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION CENTER All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5203 Power Distribution Center (PDC): Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the headlamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the headlamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the headlamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5208 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5209 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5210 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5211 Fuse: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5212 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block Fuse: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5215 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5216 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5217 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5218 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5219 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5224 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5225 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5226 Fuses (Fuse Block) - RHD Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5227 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5228 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5229 Fuse Block: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5230 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5233 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5234 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block Fuse Block: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5237 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5238 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5239 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5240 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5241 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block Fuse Block: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block > Page 5244 Fuse Block: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Fuse Block: Service and Repair Fuse Block FUSE BLOCK WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The Fuse Block is serviced with the instrument panel wire harness. If service is required to the fuse block, the entire instrument panel harness must be replaced. REMOVAL 1. Remove the instrument panel. 2. With the instrument panel removed, disassemble the instrument panel enough to gain access to all screws and connectors. 3. Remove instrument panel wire harness with fuse block. INSTALLATION 1. Install the instrument panel wire harness to the instrument panel. 2. Install all items removed from the instrument panel to gain access to the wire harness. 3. Install the instrument panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block > Page 5247 Fuse Block: Service and Repair Power Distribution Center POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Testing and Inspection Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 - 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5256 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5257 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5258 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5259 Relay Box: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5260 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5263 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5264 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5265 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5266 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5267 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center Relay Box: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center > Page 5270 Relay Box: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Page 5271 Relay Box: Service and Repair POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5276 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5277 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5278 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5279 Relay Box: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5280 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5283 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5284 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5285 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5286 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5287 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center Relay Box: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center > Page 5290 Relay Box: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Page 5291 Relay Box: Service and Repair POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Testing and Inspection Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 - 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Fig. 12 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Cigar Lighter/Power Outlet Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5327 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.1 Cigar Lighter/Power Outlet Base Removal 2. Look inside and note position of the retaining bosses (Fig. 1). 3. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. Fig.2 Cigar Lighter/Power Outlet Base Removal 4. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the same (Fig. 2). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5328 3. Push base into the bezel till it locks. 4. Install cigar lighter cap and check operation of element. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-11-2 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5332 8w-11-3 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5333 Circuit Breakers Circuit Breakers Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5334 Circuit Breaker: Diagrams Circuit Breakers - LHD Circuit Breakers - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set Diode: Customer Interest Restraint System - Erroneous Airbag DTC Set NUMBER: 08-013-03 GROUP: Electrical DATE: May 16, 2003 SUBJECT: Erroneous Airbag Diagnostic Trouble Code (DTC) - Loss of Ignition Run/Start NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves adding a diode to the L4 circuit. MODELS: 2003 (PL) Neon/SX 2.0 NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH DAYTIME RUNNING LAMPS (DRL) (SALES CODE LMN). SYMPTOM/CONDITION: Vehicle sets DTC "Loss of Ignition Run/Start". NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED FROM THE RUN POSITION TO THE OFF POSITION WHILE THE HEADLAMPS REMAIN ON. A VOLTAGE SPIKE FROM THE DAYTIME RUNNING LAMPS COULD OCCUR SETTING THE DTC. DIAGNOSIS: Using the Diagnostic Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present1 other than listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC listed above is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Open the driver's door. Remove the left instrument panel end cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5343 3. Remove the 2 fuse block mounting screws holding the fuse block to the bracket (Fig. 1). 4. Pull the fuse block and wiring harness out the instrument panel end cap opening. 5. Unwrap the wiring harness covering up to the point that the harness exits the instrument panel. 6. Locate the L4 VT/WT wire in the wiring harness going toward the instrument panel. (Fig. 2). 7. Cut the wire approximately 101.6 mm (4 in.) from the fuse block terminal. 8. Slide the heat shrink tubing over the wire and slide the tubing up the wire out of the way until needed in step 10. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5344 9. Splice in the diode kit (p/n 05107069AA) following procedures outlined in the TechCONNECT/MDS2 or 2003 Neon/SX 2.0 service manual (Publication No. 81-270-03028) page 8W-01-14 and 15 (Fig. 3). NOTE: THE DIODE IS TO BE INSTALLED WITH THE STRIPPED END AWAY FROM THE FUSE BLOCK. 10. Once the diode is soldered in place, slide the heat shrink tubing over the diode and shrink the tubing to seal the diode from the elements. 11. Install the covering on the wiring harness (Fig. 4). Apply electrical tape around the covering in a couple of places to secure. 12. Install the fuse block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5345 13. Install the 2 fuse block mounting screws. 14. Install instrument panel left end cap. 15. Install battery negative terminal. 16. Cycle the ignition switch from the RUN position to the OFF position while the headlamps are on. 17. Check DTC's in the airbag control module. 18. If the DTC does not return proceed to step 19. If the "Loss of Ignition Run/Start" DTC returns, check the installation of the diode. Be sure the stripped end of the diode is facing away from the fuse block. Repeat steps 11 through 18. NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK TO THE CORRECT TIME WHEN THE PROCEDURE IS COMPLETE. 19. Erase DTC's. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set Diode: All Technical Service Bulletins Restraint System - Erroneous Airbag DTC Set NUMBER: 08-013-03 GROUP: Electrical DATE: May 16, 2003 SUBJECT: Erroneous Airbag Diagnostic Trouble Code (DTC) - Loss of Ignition Run/Start NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves adding a diode to the L4 circuit. MODELS: 2003 (PL) Neon/SX 2.0 NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH DAYTIME RUNNING LAMPS (DRL) (SALES CODE LMN). SYMPTOM/CONDITION: Vehicle sets DTC "Loss of Ignition Run/Start". NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED FROM THE RUN POSITION TO THE OFF POSITION WHILE THE HEADLAMPS REMAIN ON. A VOLTAGE SPIKE FROM THE DAYTIME RUNNING LAMPS COULD OCCUR SETTING THE DTC. DIAGNOSIS: Using the Diagnostic Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present1 other than listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the DTC listed above is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Open the driver's door. Remove the left instrument panel end cap. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5351 3. Remove the 2 fuse block mounting screws holding the fuse block to the bracket (Fig. 1). 4. Pull the fuse block and wiring harness out the instrument panel end cap opening. 5. Unwrap the wiring harness covering up to the point that the harness exits the instrument panel. 6. Locate the L4 VT/WT wire in the wiring harness going toward the instrument panel. (Fig. 2). 7. Cut the wire approximately 101.6 mm (4 in.) from the fuse block terminal. 8. Slide the heat shrink tubing over the wire and slide the tubing up the wire out of the way until needed in step 10. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5352 9. Splice in the diode kit (p/n 05107069AA) following procedures outlined in the TechCONNECT/MDS2 or 2003 Neon/SX 2.0 service manual (Publication No. 81-270-03028) page 8W-01-14 and 15 (Fig. 3). NOTE: THE DIODE IS TO BE INSTALLED WITH THE STRIPPED END AWAY FROM THE FUSE BLOCK. 10. Once the diode is soldered in place, slide the heat shrink tubing over the diode and shrink the tubing to seal the diode from the elements. 11. Install the covering on the wiring harness (Fig. 4). Apply electrical tape around the covering in a couple of places to secure. 12. Install the fuse block. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 08-013-03 > May > 03 > Restraint System - Erroneous Airbag DTC Set > Page 5353 13. Install the 2 fuse block mounting screws. 14. Install instrument panel left end cap. 15. Install battery negative terminal. 16. Cycle the ignition switch from the RUN position to the OFF position while the headlamps are on. 17. Check DTC's in the airbag control module. 18. If the DTC does not return proceed to step 19. If the "Loss of Ignition Run/Start" DTC returns, check the installation of the diode. Be sure the stripped end of the diode is facing away from the fuse block. Repeat steps 11 through 18. NOTE: IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK TO THE CORRECT TIME WHEN THE PROCEDURE IS COMPLETE. 19. Erase DTC's. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations 1.6L and 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5357 Power Distribution Center (PDC): Application and ID Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5358 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5359 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5360 8w-10-5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5361 8w-10-6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5362 8w-10-7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5363 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION CENTER All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations > Page 5364 Power Distribution Center (PDC): Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the headlamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the headlamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the headlamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5369 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5370 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5371 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5372 Fuse: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 5373 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block Fuse: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5376 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5377 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5378 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5379 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 5380 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5385 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5386 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5387 Fuses (Fuse Block) - RHD Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5388 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5389 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5390 Fuse Block: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5391 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5394 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5395 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block Fuse Block: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5398 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5399 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5400 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5401 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 5402 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block Fuse Block: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block > Page 5405 Fuse Block: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Fuse Block: Service and Repair Fuse Block FUSE BLOCK WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The Fuse Block is serviced with the instrument panel wire harness. If service is required to the fuse block, the entire instrument panel harness must be replaced. REMOVAL 1. Remove the instrument panel. 2. With the instrument panel removed, disassemble the instrument panel enough to gain access to all screws and connectors. 3. Remove instrument panel wire harness with fuse block. INSTALLATION 1. Install the instrument panel wire harness to the instrument panel. 2. Install all items removed from the instrument panel to gain access to the wire harness. 3. Install the instrument panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block > Page 5408 Fuse Block: Service and Repair Power Distribution Center POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Testing and Inspection Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 - 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5417 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5418 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5419 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5420 Relay Box: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5421 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5424 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5425 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5426 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5427 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5428 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center Relay Box: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center > Page 5431 Relay Box: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Page 5432 Relay Box: Service and Repair POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5437 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5438 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5439 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5440 Relay Box: Locations Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 5441 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Fuse Block - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5444 Fuse Block - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5445 Fuses (Fuse Block) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5446 Fuses (Fuse Block) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5447 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 5448 Fuses (PDC) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center Relay Box: Description and Operation Power Distribution Center POWER DISTRIBUTION CENTER The Power Distribution system for this vehicle provides a safe, reliable, centralized and convenient means to access distribution of the electrical current required to operate all of the electrical systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. The power distribution system for this vehicle consist of the following components: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks - Power Distribution Center (PDC) All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just rearward of the air cleaner housing and left of the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label printed on the inside surface of the cover to ensure proper component identification. The PDC housing is secured to the left fender side extension with an indexing pin, one screw on the rail and one screw on the fender side shield. All of the PDC outputs are through the integral headlamp and dash wire harness. All of the current from the generator cable connection goes to the battery through a 140 ampere fusible link that is secured with a nut to the positive battery cable terminal. The PDC houses up to ten cartridge fuses, which replace all in-line fusible links. The PDC also houses up to 12 mini fuses (blade-type), up to three full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the PDC is faulty or damaged, the headlamp and dash wire harness assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center > Page 5451 Relay Box: Description and Operation Fuse Block FUSE BLOCK An electrical Fuse Block is located in the left end of the instrument panel. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind the left instrument panel end cap. The left end cap is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification. The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Page 5452 Relay Box: Service and Repair POWER DISTRIBUTION CENTER REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 2. Disconnect each of the head lamp and dash wire harness connectors. 3. Remove the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the head lamp and dash wire harness to the vehicle body and chassis components. 5. Disengage the grommet at the dash panel and pull connectors through. 6. Remove the two screws and disengage the PDC housing from the left inner fender well. 7. Remove the PDC and the head lamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the head lamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and head lamp and dash wire harness unit must be replaced. 1. Install the grommet at the dash panel. 2. Position the PDC in the engine compartment. 3. Align the PDC mounting pin with the inner fender well hole. 4. Place PDC down in engine compartment and install the two retaining screws. 5. Route the head lamp and dash wire harness from the PDC through the engine and passenger compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 6. Install and tighten the fasteners that secure each of the head lamp and dash wire harness ground eyelets to the vehicle body and chassis components. 7. Reconnect each of the head lamp and dash wire harness connectors. 8. Tighten nut retaining positive battery cable at PDC to 14 Nm (123 in. lbs.). 9. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Testing and Inspection Ignition Off-Draw (IOD) Fuse: Testing and Inspection STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from 5 - 35 milliamperes (0.005 - 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to 35 milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over 35 milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. 2. Determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed 35 milliamperes (0.035 ampere). If the current draw exceeds 35 milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications Alignment Specifications Alignment Specifications CURB HEIGHT FRONT REAR All Neon 26.46 ± 0.32 in (672 ± 8 mm) 26.73 ± 0.32 in. (679 ± 8 mm) SRT-4 26.97 ± 0.32 in. (685 ± 8 mm) 27.44 ± 0.32 in. (697 ± 8 mm) FRONT WHEEL ALIGNMENT ITEM PREFERRED SETTING ACCEPTABLE RANGE Standard Neon Camber 0.00° -0.40° to +0.40° Cross Camber (Max Side-to-Side Difference) 0.00° 0.50° Caster +2.60° +1.60° to +3.60° Cross Caster (Max Side-to-Side Difference) 0.00° 1.00° Total Toe +0.20° 0.00° to +0.40° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. ACR Neon Camber 0.00° -2.4° to +0.40° Cross Camber (Max Side-to-Side Difference) 0.00° 0.50° Caster +2.60° +1.60° to +3.60° Cross Caster (Max Side-to-Side Difference) 0.00° 1.00° Total Toe +0.20° -0.70° to +0.30° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. REAR WHEEL ALIGNMENT ITEM PREFERRED SETTING ACCEPTABLE RANGE Standard Neon Camber -0.25° -0.65° to +0.15° Total Toe +0.30° +0.10° to +0.50° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. Thrust Angle 0.00° -0.10° to +0.10° ACR Neon Camber -0.25° -1.00° to +0.20° Total Toe +0.30° -0.70° to +0.30° Total Toe is the sum of both the left and right wheel toe settings. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5461 setting toe. Positive toe (+) is toe-in and negative toe (-) is toe-out. Thrust Angle 0.00° -0.10° to +0.10° Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5462 Alignment: Description and Operation DESCRIPTION - WHEEL ALIGNMENT Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when Daimler Chrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front ^ Camber (when proper alignment package is used) ^ Toe Rear ^ Camber (when proper alignment package is used) ^ Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement. Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. ^ Excessive negative camber will cause tread wear at the inside of the tire. ^ Excessive positive camber will cause tread wear on the outside of the tire. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5463 CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is + 0.3° and the right camber is 0.00°, the cross camber would be + 0.3°. CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. ^ Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. ^ Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. TOE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5464 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. ^ Toe-in is produced when the front edges of the wheels on the same axle are closer together than the rear edges. ^ Toe-out is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equally distant. TOE-OUT ON TURNS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5465 Toe-out on turns is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S. A. I.) Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5466 center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I. A.) Included angle is the sum of the S.A.I. angle plus or minus the camber angle, depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I. angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). ^ Negative thrust angle means the rear tires are tracking to the left of the front tires. ^ Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment PRE-WHEEL ALIGNMENT VEHICLE INSPECTION CAUTION: If during the inspection the front suspension crossmember shows any sign of impact damage, the steering column lower coupling must be inspected. Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the 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. WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. 4. If the rear alignment is out of specification, adjust it first before proceeding to the front. CAMBER AND CASTER Front and rear camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If either front or rear camber is found not to meet alignment specifications, it can be adjusted using an available camber adjustment bolt package. Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension components for any signs of damage or bending. No adjustment can be made to the caster setting on this vehicle. If the vehicle's caster is not within alignment specifications, check for damaged suspension components or body parts. CAUTION: Do not attempt to adjust the vehicles wheel alignment by heating or bending any of the suspension components. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION (WITHOUT ACR PACKAGE) NOTE: The following procedure should be used on vehicles WITHOUT the ACR competition package or on the rear suspension of vehicles with the ACR competition package. The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provides approximately one degree of camber adjustment per side of the vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below. CAUTION: There are separate camber adjustment bolt packages for the front and rear of the vehicle. Be sure to use the correct package. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5469 2. Remove the wheel and tire assembly at the strut requiring modification. 3. Remove the original upper bolt attaching the strut clevis bracket to the knuckle. 4. Install a bolt from the adjustment package into the hole where the original bolt was removed. Install the bolt from the rear. 5. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allowing the knuckle to slide in the clevis bracket. 6. Remove the original lower bolt. 7. Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket. Install the bolt from the rear. 8. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug. 9. Reinstall the tire and wheel assembly. 10. Perform the above procedure to any of the remaining struts as required. 11. Lower the vehicle and jounce the front and rear of the vehicle. 12. Adjust the front or rear camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis bracket bolts. Again jounce the front and rear of the vehicle, then verify the camber settings. 13. Torque front strut clevis bracket-to-steering knuckle attaching bolts to 53 Nm (40 ft. lbs.), plus an additional 1/4 turn after the torque is met. Torque the rear strut clevis bracket-to-rear knuckle attaching bolts to 95 Nm (70 ft. lbs.). 14. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to TOE within this wheel alignment service procedure. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION (WITH ACR PACKAGE) NOTE: The following procedure should only be used on the front suspension of vehicles WITH the ACR competition package. For installation of the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5470 adjustment bolt package on the ACR rear suspension, refer to CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION (WITHOUT ACR PACKAGE) above. The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provides approximately one degree of camber adjustment per side of the vehicle. Additional modification will also be necessary to gain a proper camber setting for ACR competition. To modify the strut, install and adjust the camber adjustment bolt package, follow the procedure below. CAUTION: There are separate camber adjustment bolt packages for the front and rear of the vehicle. Be sure to use the correct package for the front suspension. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. 2. Remove the wheel and tire assembly at the strut requiring modification. 3. Remove the original upper and lower bolts attaching the strut clevis bracket to the knuckle. 4. Separate the knuckle from the strut clevis bracket. NOTE: The following two steps must be performed to gain the necessary amount of negative camber for ACR competition. 5. Draw an imaginary line from the center of the clevis bracket upper bolt hole down through the center of the clevis bracket lower bolt hole. Pivoting the line at the center of the lower hole, move the upper end of the line inward so as to follow an arc past the inner edge of the upper bolt hole approximately 2.8 mm (0.11 inch). Mark the bracket showing what area of the surface needs to be removed to form the elongated hole. Remember, this elongation must follow the arc. Repeat this step on the opposite side of the clevis bracket. 6. Using an appropriate grinding tool, elongate the upper hole as indicated by the markings until the necessary material is removed. Repeat this step on the opposite side of the clevis bracket. 7. Place the knuckle back in the clevis bracket. 8. Install bolts from the adjustment package into the holes where the original bolts were removed. Install the bolts from the rear. 9. Install a nut provided in adjustment package on each replacement bolt. Tighten the nuts until snug, but still allowing the knuckle to slide in the clevis bracket. 10. Reinstall the tire and wheel assembly. 11. Perform the above procedure to the remaining front strut as required. 12. Lower the vehicle and jounce the front and rear of the vehicle. 13. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis bracket bolts. Again jounce the front and rear of the vehicle, then verify the camber settings. 14. Torque front strut clevis bracket-to-steering knuckle attaching bolts to 53 Nm (40 ft. lbs.), plus an additional 1/4 turn after the torque is met. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5471 Torque the rear strut clevis bracket-to-rear knuckle attaching bolts to 95 Nm (70 ft. lbs.). 15. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When performing the toe setting procedure, make sure the rear toe is set to the preferred specification before setting the front toe to the preferred specification. REAR TOE 1. Loosen the nuts on the left and right rear lateral link attaching bolts at the rear crossmember as necessary to allow rotation of the rear toe adjustment cams. CAUTION: When adjusting rear toe, the notches on the toe adjustment cams are not to be facing down. The notches in the adjustment cams are only to be facing up or toward one side. 2. Rotate each toe adjustment cam until the preferred rear toe specification is obtained. 3. While holding the toe adjustment cams from turning, tighten the attaching bolt nuts. This will securely hold the adjustment cams in position. Tighten the attaching bolt nuts to a torque of 88 Nm (65 ft. lbs.). 4. Proceed to FRONT TOE to set the front toe. FRONT TOE CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie rod during the front toe adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5472 1. Loosen the tie rod adjusting jam nuts. Grasp each inner tie rod at its hex and rotate it one way or the other until the front wheel toe is set to the preferred specification. 2. Tighten tie rod adjusting jam nuts to a torque of 75 Nm (55 ft. lbs.). 3. Make sure the inner tie rod-to-steering gear rubber boots are not twisted. If twisted, loosen the boot clamp at the inner tie rod and move the boot as necessary. 4. Remove steering wheel clamp. 5. Remove the alignment equipment. 6. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5473 Alignment: Service and Repair Curb Height Measurement MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front an rear of the vehicle should be jounced. Induce jounce by grasping the center of the rear, then front bumper (or fascia) and jouncing the vehicle an equal number of times. Release the bumper at the bottom of the jounce cycle. 1. Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, maximum left-to-right differential is not to exceed 10 mm (0.39 inch). 3. Compare the measurements to specifications listed in the CURB HEIGHT SPECIFICATIONS chart. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation Power Steering Fluid Level Sensor/Switch: Description and Operation POWER STEERING PRESSURE SWITCH DESCRIPTION A power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality by causing a readjustment of the engine idle speed as necessary when increased fluid pressure is sensed in the power steering system. The pressure switch functions by signaling the powertrain control module that an increase in pressure of the power steering system is putting additional load on the engine. This type of condition exists when the front tires of the vehicle are turned while the vehicle is stationary and the engine is at idle speed. When the powertrain control module receives the signal from the power steering pressure switch, it directs the engine to increase its idle speed. This increase in engine idle speed compensates for the additional load, thus maintaining the required engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The switch provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. When power steering pump pressure exceeds 2758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. The PCM sends 12 volts through a resister to the sensor circuit to ground. When pump pressure is low, the switch is closed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5479 Power Steering Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding, Refer to Service Precautions . 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise the vehicle. 3. Locate the power steering fluid pressure switch on the back side of the power steering gear. 4. Remove the vehicle wiring harness connector from the power steering fluid pressure switch. NOTE: When removing and installing the power steering pressure switch, use a 7/8 inch deep well socket. The deep well socket will prevent damage to the plastic electrical connector area of the power steering fluid pressure switch. 5. Unscrew and remove the power steering fluid pressure switch from the power steering gear. INSTALLATION 1. By hand, screw the power steering pressure switch into the power steering gear until it is fully seated. Tighten the power steering pressure switch to a maximum torque of 8 Nm (70 inch lbs.). Over-torquing will result in stripping the threads out of the power steering pressure switch port in the steering gear. 2. Install the vehicle wiring harness connector. Be sure the latch on the wiring harness connector is fully engaged with the locking tab on the power steering pressure switch. 3. Lower the vehicle. 4. Fill the power steering fluid reservoir to the correct fluid level. 5. Connect the negative cable to the negative post of the battery. 6. Start the engine and turn the steering wheel several times stop-to-stop to bleed any air from the fluid in the power steering system. Stop the engine, check the fluid level, and inspect the system for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 5484 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 5485 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 5486 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5487 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications FRONT STEERING KNUCKLE: Disc Brake Caliper Guide Bolts ................................................................................................................................................ 22 Nm (192 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5492 Front Steering Knuckle: Description and Operation DESCRIPTION - STEERING KNUCKLE The steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5493 bottom, and steering linkage on the trailing end. The steering knuckle also has two machined abutments (rails) on the leading end casting to support and align the front disc brake caliper. The knuckle supports the wheel bearing and hub. The wheel hub is pressed into a sealed-for-life wheel bearing that is pressed into the steering knuckle. A retainer plate also holds the bearing in place. The hub supports the driveshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a nut retainer and cotter pin. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub has five studs pressed into its flange. OPERATION - STEERING KNUCKLE The steering knuckle pivots with the strut assembly between the lower ball joint and the pivot bearing in the strut assembly. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub, wheel bearing and axle shaft. The hub and wheel bearing work together. The wheel bearing has internal bearings that allow the hub to rotate with the driveshaft and the tire and wheel assembly. The hub's five studs mount the tire and wheel to the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5494 Front Steering Knuckle: Testing and Inspection DIAGNOSIS AND TESTING - STEERING KNUCKLE 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5495 Front Steering Knuckle: Service and Repair REMOVAL - STEERING KNUCKLE NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Apply the brakes and hold in place. 2. Raise the vehicle. 3. Remove the front tire and wheel assembly. 4. Remove the cotter pin, lock nut and spring washer from the hub nut. 5. While the brakes are applied, loosen and remove the hub nut. 6. Release the brakes. 7. Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle. 8. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side) or bottom (left side) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide (on the knuckle) and rotor. 9. Hang the caliper out of the way using a wire hanger or cord. Do not support the caliper by letting it hang by the hydraulic hose. 10. Remove any retainer clips from the wheel mounting studs. Remove the brake rotor from the front hub. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5496 11. Remove the nut attaching the outer tie rod to the steering knuckle. To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 12. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB991113. 13. Remove the tie rod heat shield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5497 14. Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle. CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckles while removing the nuts, then tap the bolts out using a pin punch. 15. Remove the two bolts attaching the strut to the steering knuckle. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. 16. Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle. NOTE: Do not allow the driveshaft to hang by the inner ON joint; it must be supported to keep the joint from separating during this operation. 17. Pull the steering knuckle off the driveshaft outer C/V joint splines and remove the steering knuckle. NOTE: 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 wheel bearing, a new bearing must be installed in the steering knuckle. Installation of the new wheel bearing and hub must be done before installing the steering knuckle on the vehicle. 18. If the steering knuckle is to be replaced, the hub and wheel bearing must be removed. Do not reuse the wheel bearing. DISASSEMBLY- STEERING KNUCKLE (WHEEL BEARING AND HUB) NOTE: The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle. Removal of the wheel bearing from the steering knuckle must be done using the following procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5498 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. 2. Using Remover, Special Tool 41 50A, press one wheel mounting stud out of hub flange. Rotate the hub to align the removed wheel mounting stud with the notch in bearing retainer plate. Remove the wheel mounting stud from the hub. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5499 3. Rotate the hub so the hole in the hub that wheel mounting stud was removed from is facing away from brake caliper lower rail on steering knuckle. Install one half of the Bearing Splitter, Special Tool 1130, between the hub and the bearing retainer plate. NOTE: Align the threaded hole in this first half of the bearing splitter with the caliper rail on the steering knuckle. 4. Install the remaining pieces of Bearing Splitter, Special Tool 1130, on the steering knuckle. Hand tighten the nuts to hold bearing splitter in place on steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5500 5. Once the bearing splitter in fully installed, be sure the three bolts attaching the bearing retainer plate to steering knuckle are contacting the bearing splitter. The bearing retainer plate should not support the steering knuckle or contact the bearing splitter. 6. Place the steering knuckle in an arbor press supported by the bearing splitter as shown. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5501 7. Position Driver, Special Tool 6644-2, on the small end of the hub. Using the arbor press, remove the hub from the wheel bearing. The outer bearing race will normally come out of the wheel bearing when the hub is pressed out of the bearing. 8. Remove the bearing splitter from the steering knuckle. 9. Remove the three bolts mounting the bearing retainer plate to the steering knuckle. Remove the bearing retainer plate from the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5502 10. Place the steering knuckle back in the arbor press supported by press blocks as shown. The press blocks must not obstruct the bore in the steering knuckle so the wheel bearing can be pressed out of the steering knuckle. Place Bearing Driver, Special Tool MB-990799 on the outer race of wheel bearing. Press the wheel bearing out of the steering knuckle. 11. Install Bearing Splitter, Special Tool 1130, on the hub. The bearing splitter is to be installed on the hub so it is between the flange of the hub and the outer bearing race on the hub. Place the hub, bearing race and bearing splitter in an arbor press as shown. Place Driver, Special Tool 6644-2 on end of hub. Press the hub out of the outer bearing race. ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB) NOTE: The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle. 1. Wipe the empty bore of the steering knuckle clean of any grease or dirt with a clean, dry shop towel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5503 2. Place the new wheel bearing into the bore of the steering knuckle. Be sure the wheel bearing is placed squarely into the bore. Place the steering knuckle in an arbor press with Receiver, Special Tool C-4698-2, supporting the steering knuckle. Place Driver, Special Tool 5052, on the outer race of the wheel bearing. Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle. Remove the knuckle from the press. NOTE: Only the original or identical replacement bolts are to be used to mount the bearing retainer plate to the steering knuckle. 3. Install the bearing retainer plate on the steering knuckle. Install the three bearing retainer mounting bolts. Tighten the bearing retainer plate mounting bolts to a torque of 28 Nm (250 inch lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5504 4. Place the previously removed wheel mounting stud back into the hub flange. Place the hub in the arbor press supported by Special Tool C-4698-1. Press wheel mounting stud into hub flange until it is fully seated against the back side on the hub flange. Remove the hub from the press. 5. Place the steering knuckle with the wheel bearing installed back in the arbor press with Receiver, Special Tool MB-990799 supporting the inner race of the wheel bearing as shown. Place the hub in wheel bearing making sure it is square with the bearing inner race. Press the hub into the wheel bearing until it is fully bottomed in the wheel bearing. Remove the knuckle from the press. 6. Install the steering knuckle assembly on the vehicle. INSTALLATION - STEERING KNUCKLE 1. If the steering knuckle is being replaced and the wheel bearing and hub must be installed. Do not reuse the old wheel bearing. 2. Slide the hub of the steering knuckle onto the splines on the driveshaft C/V joint. 3. Install the steering knuckle onto the ball joint stud aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud. 4. Install a new ball joint stud pinch bolt and nut. Tighten the nut to a torque of 95 Nm (70 ft. lbs.). CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. 5. Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes. Install the two attaching bolts. The bolts should be installed with so that the nuts face towards the front of the vehicle once installed. Install the nuts. Holding the bolts in place tighten the nuts to a torque of 53 Nm (40 ft. lbs.) plus an additional 90° turn after the specified torque is met. 6. Place the tie rod heat shield on the steering knuckle arm so that the shield is positioned straight away from the steering gear and tie rod end once Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5505 installed. Align the hole in the shield with the hole in the steering knuckle arm. 7. Install the outer tie rod ball stud into the hole in the steering knuckle arm. Start the tie rod attaching nut onto the stud. Hold the tie rod end stud with a wrench while tightening the nut with a standard wrench or crowfoot wrench. To fully tighten the nut to specifications, use a crowfoot wrench on a torque wrench to turn the nut, and a wrench on the stud. Tighten the nut to a torque of 55 Nm (40 ft. lbs.). 8. Install the brake rotor on the hub. 9. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 10. Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 11. Clean all foreign matter from the threads of the driveshaft outer C/V joint. 12. Install the hub nut in the end of the driveshaft and snug it. 13. Have a helper apply the brakes. With vehicle brakes applied to keep brake rotor and hub from turning, tighten the hub nut to a torque of 244 Nm (180 ft. lbs.). 14. Install the spring washer, lock nut and cotter pin on the hub nut. Wrap the cotter pin ends tightly around the lock nut. 15. Install the tire and wheel assembly. Install the wheel mounting nuts and tighten them to a torque of 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Set front toe on the vehicle to specification. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5511 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5512 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5513 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications The power steering pump has a dipstick. Fluid should be maintained at the proper level indicated on the dipstick. CAUTION: The power steering fluid should be checked on a level surface with the engine off. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 5516 Power Steering Fluid: Fluid Type Specifications Automatic Transmission Fluid Type Automatic Transmission Fluid Type Mopar ATF+4, Automatic Transmission Fluid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5517 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602) in the power steering system. Do not overfill the system. The power steering fluid level can be viewed on the dipstick attached to the filler cap. Before opening the power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on the dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should register between the ADD and FULL markings on the dipstick. The optimum level is at the FULL line. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation Power Steering Fluid Cooler: Description and Operation DESCRIPTION All models of this vehicle are equipped with a cooler for the power steering system fluid. The purpose of the cooler is to keep the temperature of the power steering system fluid from rising to a level that would affect the performance of the power steering system. The power steering fluid cooler is located at the front of the front suspension crossmember. It is mounted to the crossmember top surface using 2 fasteners. The cooler is placed in series with the power steering fluid return hose, between the steering gear fluid outlet port and the fluid return hose leading to the power steering fluid reservoir. The power steering gear has a steel fitting attached to its outlet port that a short hose leading to the cooler is pushed onto. This hose is secured to both the steering gear outlet fitting and the cooler using standard adjustable clamps. The cooler is secured to the power steering fluid return hose using a standard adjustable clamp. OPERATION The cooler used on this vehicle is referred to as a fluid-to-air type cooler. This means that the air flow across the tubes of the cooler is used to extract the heat from the cooler which it has absorbed from the power steering fluid flowing through it. Utilizing a small air dam mounted to its base to redirect air across its coils, the cooler lowers the temperature of the power steering fluid prior to it entering the power steering fluid reservoir where it is resupplied to the power steering pump. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation > Page 5521 Power Steering Fluid Cooler: Service and Repair REMOVAL NOTE: Before proceeding, Service Precautions. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. 3. Remove the hose clamp attaching the power steering fluid return hose to the power steering fluid cooler. Remove the return hose from the cooler. Power Steering Fluid Cooler Removal Part 1 Of 2 Power Steering Fluid Cooler Removal Part 2 Of 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation > Page 5522 4. Remove the hose clamp attaching the power steering cooler fluid hose to the steel fitting in the power steering gear outlet port. 5. Remove the two screws securing the cooler to the front suspension crossmember. 6. On LHD vehicles, open the tube routing clamp on the right front of the power steering gear housing and remove the cooler tube from it. 7. Remove the cooler from the vehicle. INSTALLATION 1. Slide a hose clamp onto the end of the power steering cooler inlet hose (gear end) far enough to clear the steel fitting on the power steering gear once the hose is installed. 2. On LHD vehicles, align the cooler outlet tube with the open tube routing clamp on the right front of the power steering gear housing, and snap it into place. Close the clamp. 3. Slide the hose (with cooler attached) onto the steering gear outlet fitting. 4. Install the hose clamp on the power steering cooler fluid hose past the bead formed into the steel fitting and secure in place. 5. Install the two screws attaching the cooler to the front suspension crossmember. Tighten the cooler attaching screws to a torque of 10 Nm (90 inch lbs.). 6. Install the power steering fluid return hose on the power steering fluid cooler outlet tube. Install the hose clamp on the power steering return hose securing it to the power steering cooler. Be sure the hose clamp is installed on the return hose past the bead on the end of the cooler tube. 7. Lower the vehicle. 8. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. 9. Check for leaks at all connections. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation Power Steering Fluid Level Sensor/Switch: Description and Operation POWER STEERING PRESSURE SWITCH DESCRIPTION A power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality by causing a readjustment of the engine idle speed as necessary when increased fluid pressure is sensed in the power steering system. The pressure switch functions by signaling the powertrain control module that an increase in pressure of the power steering system is putting additional load on the engine. This type of condition exists when the front tires of the vehicle are turned while the vehicle is stationary and the engine is at idle speed. When the powertrain control module receives the signal from the power steering pressure switch, it directs the engine to increase its idle speed. This increase in engine idle speed compensates for the additional load, thus maintaining the required engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The switch provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. When power steering pump pressure exceeds 2758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. The PCM sends 12 volts through a resister to the sensor circuit to ground. When pump pressure is low, the switch is closed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5526 Power Steering Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding, Refer to Service Precautions . 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise the vehicle. 3. Locate the power steering fluid pressure switch on the back side of the power steering gear. 4. Remove the vehicle wiring harness connector from the power steering fluid pressure switch. NOTE: When removing and installing the power steering pressure switch, use a 7/8 inch deep well socket. The deep well socket will prevent damage to the plastic electrical connector area of the power steering fluid pressure switch. 5. Unscrew and remove the power steering fluid pressure switch from the power steering gear. INSTALLATION 1. By hand, screw the power steering pressure switch into the power steering gear until it is fully seated. Tighten the power steering pressure switch to a maximum torque of 8 Nm (70 inch lbs.). Over-torquing will result in stripping the threads out of the power steering pressure switch port in the steering gear. 2. Install the vehicle wiring harness connector. Be sure the latch on the wiring harness connector is fully engaged with the locking tab on the power steering pressure switch. 3. Lower the vehicle. 4. Fill the power steering fluid reservoir to the correct fluid level. 5. Connect the negative cable to the negative post of the battery. 6. Start the engine and turn the steering wheel several times stop-to-stop to bleed any air from the fluid in the power steering system. Stop the engine, check the fluid level, and inspect the system for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Capacity Specifications Power Steering Fluid Reservoir: Capacity Specifications The power steering pump has a dipstick. Fluid should be maintained at the proper level indicated on the dipstick. CAUTION: The power steering fluid should be checked on a level surface with the engine off. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Capacity Specifications > Page 5531 Power Steering Fluid Reservoir: Fluid Type Specifications Automatic Transmission Fluid Type Automatic Transmission Fluid Type Mopar ATF+4, Automatic Transmission Fluid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ..................................................... 34 Nm (25 ft. lbs.) Return Hose Bracket Bolt .................................................................................................................................................. 28 Nm (21 ft. lbs., 250 inch lbs.) Pressure Hose Bracket Bolt ........................................................................ .............................................................................................. 61 Nm (45 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure HOSE POWER STEERING PRESSURE REMOVAL NOTE: Before proceeding, Service Precautions. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. Hoses And Cooler At LHD Gear Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 5537 Hoses And Cooler At RHD Gear 3. Back out the tube nut securing the power steering fluid pressure hose to the gear. 4. LHD only Open the tube clamp on the right side of the gear and release the tube from the clamp. 5. Remove the pressure hose tube from the gear. RHD Pressure Hose At Engine 6. RHD only - Remove the bolt securing the pressure hose bracket to the engine. 7. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 5538 Power Steering Hoses At Pump 8. Remove the bolt securing the hose routing bracket to the engine mount dragon head. Remove the hose from the bracket. 9. Un-thread the tube nut securing the power steering pressure hose to the power steering pump. 10. Remove the power steering pressure hose. INSTALLATION 1. Install the power steering pressure hose into the engine compartment from the top. First, guide the pump end of the hose under the pump, then route the rest of the hose along the right side of the engine. Guide the gear end of the hose down behind the engine towards the power steering gear. 2. Using a lint free towel, wipe clean the open power steering hose end and the power steering pump port. Replace the used O-ring with new. Lubricate the O-ring with clean power steering fluid. 3. Install the power steering pressure hose into the outlet fitting on the bottom of the power steering pump. 4. Thread the tube nut into the pump outlet fitting and tighten it to a torque of 34 Nm (25 ft. lbs.). 5. Install the hose into the hose routing bracket aligning it as shown and attach the bracket to the engine mount dragon head along with the ground strap. Tighten the screw to a torque of 12 Nm (105 inch lbs.). 6. Raise the vehicle. CAUTION: The power steering fluid hoses must remain away from the exhaust system, vehicle components, and unfriendly surfaces that can cause possible damage to the power steering hoses. 7. RHD only - Install the bolt attaching the power steering fluid pressure hose routing clamp to the engine. Tighten the bolt to a torque of 61 Nm (45 ft. lbs.). 8. Using a lint free towel, wipe clean the open power steering hose end and the power steering gear port. Replace the used O-ring with new. Lubricate the O-ring with clean power steering fluid. 9. Attach the power steering fluid pressure hose to the port on the power steering gear. Start the tube nut threads into the gear. Do not completely tighten at this time. 10. LHD only - Open the tube clamp on the right side of the gear and insert the pressure hose tube. Close the clamp. 11. Tighten the pressure hose tube nut at the gear to a torque of 34 Nm (25 ft. lbs.). 12. Lower the vehicle. 13. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. 14. Check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 5539 Power Steering Line/Hose: Service and Repair Hose - Return HOSE POWER STEERING RETURN REMOVAL NOTE: Before proceeding, Service Precautions. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. Hoses And Cooler At LHD Gear Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 5540 Hoses And Cooler At RHD Gear 3. Remove the hose clamp securing the return hose to the power steering cooler tube. Slide the hose off the end of the cooler tube. 4. Lower the vehicle. Power Steering Hoses At Pump 5. Remove the hose clamp securing the return hose to the power steering fluid reservoir. Slide the hose off the end of the reservoir fitting. 6. Remove the bolt securing the hose routing bracket to the engine mount dragon head. Remove the hose from the bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 5541 INSTALLATION 1. Slide a hose clamp onto the power steering pump end of the hose far enough to clear the fitting on the power steering fluid reservoir once the hose is installed. 2. Install the power steering return hose into the engine compartment from the top. First, guide the pump end of the hose onto the fitting of the power steering pump fluid reservoir, then route the rest of the hose along the right side of the engine. Guide the remaining end of the hose down behind the engine towards the power steering gear. 3. Expand the hose clamp and slide it onto the fluid reservoir fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 4. Install the hose into the hose routing bracket aligning it as shown and attach the bracket to the engine mount dragon head along with the ground strap. Tighten the screw to a torque of 12 Nm (105 inch lbs.). 5. Raise the vehicle. CAUTION: The power steering fluid hoses must remain away from the exhaust system, vehicle components, and unfriendly surfaces that can cause possible damage to the power steering hoses. 6. Using a lint free towel, wipe clean the open power steering hose end and the power steering fluid cooler tube. 7. Install a hose clamp onto the end of the hose far enough to clear the fitting on the cooler once the hose is installed. 8. Slide the hose onto the end of the cooler tube. Install the hose clamp past the bead formed into the cooler tube and secure in place. 9. Lower the vehicle. 10. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. 11. Check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5546 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5547 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5548 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Pump Pressure Fitting ......................................................................................................................... ...................................................... 88 Nm (65 ft. lbs.) Pump Mounting Bolts ........................................................................................................................................................ 28 Nm (21 ft. lbs., 250 inch lbs.) Pump Rear Bracket-To-Engine Bolts ....................................................................................................................................................... 54 Nm (40 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5551 Power Steering Pump: Pressure, Vacuum and Temperature Specifications POWER STEERING PUMP FLOW Flow At 1500 RPM And Minimum Pressure ................................................................................................................................. 5.67 - 6.43 Liters/Min .............................................................................................................................................................. ............................................................ 1.5-1.7 GPM Control Valve Relief Pressure ............................................................................................................. ..................................................... 9308 - 9998 kPa .............................................................................................................................................................. ......................................................... 1350- 1450 psi Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5552 Power Steering Pump: Description and Operation DESCRIPTION - POWER STEERING PUMP (2.0L ENGINE) The hydraulic pressure for operation of the power steering gear is provided by a belt driven power steering pump. The constant flow rate and displacement vane-type power steering pump is located on the front corner of the engine. No repair procedures are to be done on the internal components of the power steering pump. The only serviceable components of the power steering pump are the power steering pump pulley and the pump itself. The power steering fluid reservoir is serviced with the pump. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Initial Operation STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION WARNING: THE FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602) in the power steering system. Do not overfill. 1. Fill the power steering fluid reservoir to the proper level, then let the fluid settle for at least two 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. Removal and Installation REMOVAL - POWER STEERING PUMP NOTE: Before proceeding, Description and Operation. 1. Remove battery cable from the negative post on the battery. 2. Siphon as much fluid as possible from the power steering fluid reservoir. 3. Remove the power steering pump drive belt from the power steering pump pulley. 4. Remove the hose clamp securing the return hose to the power steering fluid reservoir. Slide the hose off the end of the reservoir fitting. 5. Back out the tube nut securing the power steering fluid pressure hose to the power steering pump, then remove the hose from the pump. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5555 6. Remove the mounting bolt securing the support bracket to the rear of the power steering pump. 7. Loosen the two mounting bolts securing the support bracket to the engine block. 8. Remove the three mounting bolts holding the power steering pump to the cast bracket. Access to the mounting bolts can be achieved through the holes in the pump pulley. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5556 NOTE: It may be necessary to remove the screw holding the A/C line routing clamp to the radiator upper closure panel. 9. Remove the power steering pump with reservoir from the engine. 10. For transferal of the power steering pump pulley, Refer to PUMP - DISASSEMBLY. INSTALLATION - POWER STEERING PUMP 1. Install the power steering pump with reservoir and pulley on the engine and install the three mounting bolts securing the pump to the cast bracket. Tighten the three bolts to a torque of 28 Nm (250 inch lbs.). 2. Install the mounting bolt securing the support bracket to the rear of the power steering pump. Do not completely tighten the bolt at this time. 3. Install the two mounting bolts securing the support bracket to the engine block. Tighten the bolts to a torque of 54 Nm (40 ft. lbs.). 4. Tighten the mounting bolt securing the support bracket to the rear of the power steering pump to a torque of 28 Nm (250 inch lbs.). 5. Install the power steering pump drive belt on the power steering pump pulley. 6. Using a lint free towel, wipe clean all open power steering hose ends and power steering pump fittings. 7. Install a new O-ring on the end of the power steering pressure hose. Lubricate the O-ring using clean power steering fluid. 8. Attach the power steering fluid pressure hose to the pressure fitting on the lower end of the power steering pump. Thread the tube nut securing the power steering fluid pressure hose into the power steering pump pressure fitting. Tighten the tube nut to at torque of 34 Nm (25 ft. lbs.). 9. Slide the power steering fluid return hose onto the fluid reservoir fitting. Position the hose clamp so it is installed on the hose past the bead formed into the fluid reservoir fitting. 10. If previously disconnected, attach the A/C line routing clamp to the radiator upper closure panel. 11. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. 12. Check for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5557 Power Steering Pump: Service and Repair Power Steering Pump Pulley DISASSEMBLY - POWER STEERING PUMP (PULLEY) NOTE: The only serviceable part of the power steering pump is the pulley. Use the following procedure for removal of the pulley from the pump. NOTE: The power steering pump must be removed from the vehicle for power steering pump pulley service. CAUTION: Use care when removing and installing the power steering pump pulley. It is made of plastic composite, except for the center shank. The special tools are to be used in the shank area only as described in the following procedure. CAUTION: Do not hammer on the power steering pump pulley or shaft to remove the power steering pump pulley. Damage to the pulley and the power steering pump can occur. 1. Install Puller, Special Tool C-4333, or an equivalent, on the steering pump pulley as shown. Tighten the puller screw drive and remove the pulley from the power steering pump shaft. NOTE: Replace the power steering pump pulley if it is cracked or loose. 2. Remove the puller from the power steering pump pulley. NOTE: For installation of the pulley, Refer to PUMP - ASSEMBLY. ASSEMBLY - POWER STEERING PUMP (PULLEY) CAUTION: Use care when removing and installing the power steering pump pulley. It is made of plastic composite, except for the center shank. The special tools are to be used in the shank area only as described in the following procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5558 1. Place the power steering pump pulley squarely on end of the power steering pump shaft. Mount Installer, Special Tool C-4063, or an equivalent, in the internal threads of the power steering pump shaft and against power steering pump pulley. 2. Ensuring that the installer and the pulley remain aligned with pump shaft, turn the installer outer nut and force the pulley onto the power steering pump shaft until it is flush with the end of the pump shaft. Once the pulley is flush with the end of the shaft, the installer outer nut will no longer be able to turn. 3. Remove the installer from the power steering pump. 4. Install the power steering pump back on the engine. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation Power Steering Fluid Level Sensor/Switch: Description and Operation POWER STEERING PRESSURE SWITCH DESCRIPTION A power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality by causing a readjustment of the engine idle speed as necessary when increased fluid pressure is sensed in the power steering system. The pressure switch functions by signaling the powertrain control module that an increase in pressure of the power steering system is putting additional load on the engine. This type of condition exists when the front tires of the vehicle are turned while the vehicle is stationary and the engine is at idle speed. When the powertrain control module receives the signal from the power steering pressure switch, it directs the engine to increase its idle speed. This increase in engine idle speed compensates for the additional load, thus maintaining the required engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The switch provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. When power steering pump pressure exceeds 2758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. The PCM sends 12 volts through a resister to the sensor circuit to ground. When pump pressure is low, the switch is closed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5563 Power Steering Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding, Refer to Service Precautions . 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise the vehicle. 3. Locate the power steering fluid pressure switch on the back side of the power steering gear. 4. Remove the vehicle wiring harness connector from the power steering fluid pressure switch. NOTE: When removing and installing the power steering pressure switch, use a 7/8 inch deep well socket. The deep well socket will prevent damage to the plastic electrical connector area of the power steering fluid pressure switch. 5. Unscrew and remove the power steering fluid pressure switch from the power steering gear. INSTALLATION 1. By hand, screw the power steering pressure switch into the power steering gear until it is fully seated. Tighten the power steering pressure switch to a maximum torque of 8 Nm (70 inch lbs.). Over-torquing will result in stripping the threads out of the power steering pressure switch port in the steering gear. 2. Install the vehicle wiring harness connector. Be sure the latch on the wiring harness connector is fully engaged with the locking tab on the power steering pressure switch. 3. Lower the vehicle. 4. Fill the power steering fluid reservoir to the correct fluid level. 5. Connect the negative cable to the negative post of the battery. 6. Start the engine and turn the steering wheel several times stop-to-stop to bleed any air from the fluid in the power steering system. Stop the engine, check the fluid level, and inspect the system for leaks. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 5568 Power Steering Pressure Switch: Connector Locations Fig. 2 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 5569 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Component Locations > Page 5570 Fig. 40 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5571 Power Steering Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5576 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Column Bearing: Customer Interest Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5585 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5586 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5587 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5588 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Column Bearing: All Technical Service Bulletins Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5594 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5595 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5596 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5597 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Column Cover: Customer Interest Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5606 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5607 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5608 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5609 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Column Cover: All Technical Service Bulletins Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5615 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5616 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5617 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Cover: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5618 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation Steering Gear: Description and Operation DESCRIPTION - POWER STEERING GEAR The power steering gear is mounted on the front suspension crossmember. The outer ends of the outer tie rods attach to the steering knuckles. There are two different type power steering gears used on this vehicle, a standard, and an optional which is used on the ACR and R/T vehicles. Externally the gears appear the same. Internally, the standard has a 16:1 turning ratio while the ACR /R/T gear has an 18:1 turning ratio. The gear used on ACR and R/T vehicles also has a restricted lateral (lock-to-lock) travel range to accommodate the R/T wheel and tire combination. Sport feel valve coding provides ACR / R/T vehicles with more firm feel steering to match the performance tire compounding and construction. 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. OPERATION - POWER STEERING GEAR Turning of the steering wheel is converted into lateral (side-to side) travel through the meshing of the helical pinion teeth with the rack teeth located in the steering gear. This lateral travel pushes and pulls the tie rods to change the direction of the vehicle's front wheels. Power assist is provided by a pump and is controlled by an open-center, rotary type control valve. It directs fluid to either side of the gear's integral steering rack piston. Depending on the rotation of the steering wheel, more fluid pressure is directed to one side of the rack piston compared to the other. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As steering effort increases, as in a turn, the torsion bar twists causing relative rotary motion between the rotary valve body and valve spool. This movement restricts fluid flow to one side of the integral rack piston and redirects fluid behind the other side of the integral rack piston, building up hydraulic pressure, thus assisting in the turning effort. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5622 Steering Gear: Service and Repair REMOVAL - POWER STEERING GEAR NOTE: Before proceeding with this procedure, Refer to STEERING - Service Precautions. 1. Place the steering wheel in the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation. 2. Inside the passenger compartment, remove the steering column coupling retainer pin, back off the pinch bolt nut, and remove the steering column coupling pinch bolt (the pinch bolt nut is caged to the coupling and is not removable). Separate the upper and lower steering column couplings. 3. Raise the vehicle. 4. Remove both front tire and wheel assemblies from the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5623 5. Remove nuts attaching both outer tie rods to the steering knuckles. Remove each nut by holding the tie rod stud stationary while loosening and removing the nut with a wrench. 6. Remove the outer tie rod from the steering knuckles using Remover, Special Tool MB99 1113. 7. Remove the tie rod heat shield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5624 8. Release the locking tab on the wiring harness connector for the power steering fluid pressure switch before connector removal. Remove the wiring harness connector from the power steering fluid pressure switch. 9. Back out the tube nut securing the power steering fluid pressure hose to the gear. 10. Loosen the clamp, then disconnect the fluid cooler hose from the gear. 11. Open the routing clips on the front of the power steering gear and remove the power steering fluid pressure hose from the routing clips. At the same time, remove the cooler tube from the right routing clip. 12. Remove the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler and can be accessed from above. Allow the cooler to hang out of the way. 13. Remove the drive-belt splash shield fasteners. Remove the shield. 14. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle. Remove the washer behind the strut from the torque strut bolt. 15. Remove the bolts mounting the engine torque strut in place, then remove the engine torque strut from the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5625 NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be scribed on the body of the vehicle. Do this so that the crossmember can be relocated upon reinstallation against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost. 16. Using an awl, scribe a line marking the location of where the front suspension crossmember is mounted against the body of the vehicle. 17. Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember. 18. Loosen and completely remove the two front bolts (one right and one left) attaching the front suspension crossmember to the frame rails of vehicle. The right side bolt can be viewed in the mounting bolt figure. The left side bolt is located in the same location on the other side of the vehicle. 19. Loosen the two rear bolts (one right and one left) attaching the front suspension crossmember and lower control arms to the body of the vehicle until they release from the threaded tapping plates in the body of the vehicle. Do not completely remove the rear bolts because they are designed to disengage from the body threads yet stay within the lower control arm rear isolator bushing. This allows the lower control arm to stay in place on the crossmember. The right side bolt can be viewed in the mounting bolt figure. The left side bolt is located in the same location on the other side of the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5626 20. Lower the front suspension crossmember using the transmission jack enough to allow the power steering gear to be removed from the rear of the crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms. The weight should be supported by the transmission jack. 21. Remove the roll pin securing the steering column lower coupling to the power steering gear pinion shaft using a roll pin punch. Push the steering column lower coupling up and off of the power steering gear pinion shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5627 22. Release the pinion shaft dash cover seal from the tabs cast into the power steering gear housing and remove the seal from the power steering gear. 23. Loosen and remove the four bolts attaching the power steering gear to the front suspension crossmember. Remove the power steering gear from the front suspension crossmember. REMOVAL - RHD Right-Hand-Drive power steering gear is typical of Left-Hand-Drive. INSTALLATION - POWER STEERING GEAR 1. Install the steering gear on the front suspension crossmember. Install the four power steering gear mounting bolts. Tighten the mounting bolts to a torque of 61 Nm (45 ft. lbs.). 2. Install the pinion shaft dash cover seal over the power steering pinion shaft and onto the power steering gear housing. Align the holes on each side of the seal with the tabs cast into the power steering gear housing. 3. With the steering column lower coupling pushed partway up through its hole in the dash panel, match the flat on the inside of the steering column lower coupling to the flat on the power steering gear pinion shaft and slide the coupling onto the top of the pinion shaft. Align the roll pin hole in the coupling with the groove in the pinion shaft and install the roll pin through the coupling until it is centered. 4. Center the power steering gear rack in its travel. 5. Using the transmission jack, raise the front suspension crossmember and power steering gear until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the steering column lower coupling up through its hole in the dash panel. 6. Start the two rear crossmember mounting bolts into the tapping plates mounted in the body. The right side bolt can be viewed in the mounting bolt figure. The left side bolt is located in the same location on the other side of the vehicle. Next, install the two front mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all four mounting bolts to a approximately 2 Nm (20 inch lbs.) to hold the front suspension crossmember in position. NOTE: When reinstalling the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost. 7. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle. Once the front suspension crossmember is correctly positioned, tighten the rear two crossmember (and rear lower control arm) mounting bolts to a torque of 203 Nm (150 ft. lbs.), then tighten the front two crossmember mounting bolts to a torque of 142 Nm (105 ft. lbs.). 8. Install the engine torque strut and mounting bolts. To properly align and tighten the torque strut, Refer to TORQUE STRUT - ADJUSTMENTS. 9. Install the washer on the end of the stud extending from the torque strut bolt. 10. Install the pencil strut to the right front corner of the crossmember and body of the vehicle. Tighten the pencil strut nuts to a torque of 58 Nm (43 ft. lbs.). 11. Install the drive-belt splash shield and fasteners. 12. Using a lint free towel, wipe clean the open power steering hose ends and the power steering gear ports. Replace the pressure hose used O-ring with new. Lubricate the O-ring with power steering fluid. 13. Attach the power steering fluid pressure hose to the pressure port on the power steering gear. Start the tube nut threads into the gear, but do not tighten them at this time. On vehicles equipped with a power steering fluid cooler, reconnect the cooler line to the gear in place of the power steering fluid return hose. 14. Open the routing clips on the front of the steering gear housing and install the power steering fluid pressure hose into the routing clips. 15. Place the cooler in mounting position and snap the cooler tube going to the gear into the right routing clip. 16. Close both routing clips. 17. Tighten the power steering fluid pressure hose tube nut at the gear to a torque of 34 Nm (25 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5628 18. Install the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler. 19. Place the hose clamp on the hose far enough from the end to clear the steel fitting on the gear. Do the same for the fluid return hose on a vehicle that is not equipped with a cooler. 20. Push either hose listed in the above step onto the steel fitting, then move and secure the clamp on the hose past the bead on the steel fitting in the steering gears outlet port. 21. Route the fluid return hose along the front of the steering gear, clipping it into place in the C-clamps on the outside of the routing clips on the front of the power steering gear housing. 22. Reconnect the wiring harness connector from the power steering fluid pressure switch. Be sure the locking tab on the wiring harness connector is securely latched. 23. Perform the following to each outer tie rod: ^ Place the tie rod heat shield on the knuckle's steering arm, aligning the hole in the shield with the hole in the knuckle and the tangs on the outside of the shield with the outside configuration of the steering arm. The shield should now be facing outboard, away from the power steering gear and tie rod. ^ Attach the outer tie rod end to its steering knuckle. ^ Start the attaching nut onto the stud of the outer tie rod. ^ While holding the stud of the tie rod stationary with a wrench, tighten the attaching nut. ^ Using a crowfoot wrench attached to a torque wrench, tighten the attaching nut to 55 Nm (40 ft. lbs.). 24. Install the tire and wheel assemblies back on vehicle. Tighten the wheel mounting nuts to 135 Nm (100 ft. lbs.) torque. 25. Lower the vehicle to ground level. 26. Install the dash-to-lower coupling seal in place over the lower coupling's plastic collar. NOTE: Verify that grease is present on the lip of the dash-to-coupling seal where it contacts the coupling's plastic collar. 27. Inside the passenger compartment, place the steering column in the full tilt-up position and secure the tilt lever, then reconnect the steering column lower coupling to the steering column upper coupling. Install the coupling pinch bolt and tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.). Install the pinch bolt retainer pin. 28. Remove the steering wheel holder. 29. While looking under the instrument panel at the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does not squeak against the dash-to-coupling seal. 30. Perform the POWER STEERING PUMP INITIAL OPERATION service procedure to properly fill and bleed the power steering system. 31. Check for fluid leaks. 32. Adjust the front toe setting on the vehicle. INSTALLATION - RHD Right-Hand-Drive power steering gear is typical of Left-Hand-Drive. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Shaft: Customer Interest Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5637 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5638 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5639 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5640 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Shaft: All Technical Service Bulletins Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5646 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5647 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5648 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5649 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Shaft Coupler: Customer Interest Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5658 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5659 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5660 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5661 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Shaft Coupler: All Technical Service Bulletins Steering - Steering Column Clicking Sound NUMBER: 19-002-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-002-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2000 - 2004 (PL) Neon NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH 1116XX). SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or service information on TeChCONNECT for removal and installation procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5667 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow the system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft from the steering column shaft. Install Remover/Installer, Special Tool 6831-A, through center of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5668 roll pin in intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft, refer to (Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. Refer to (Fig. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5669 2) 21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n 04690570, and **revised preload spring, p/n 05057088AA**. 22. Thread the steering wheel bolt into the steering column shaft. 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 19-002-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 5670 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). NOTE: If the installed dimension is less than l2mm a binding condition may result. If the installed dimension is greater than l4mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column and intermediate shaft assembly into the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Page 5671 Steering Shaft Coupler: Description and Operation STEERING COUPLING LOWER DESCRIPTION This vehicle uses a corrugated design lower coupling to connect the steering column to the steering gear. This coupling has a hollow corrugated tube that allows the coupling to bend rather than collapse when a vehicle is involved in a collision. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Page 5672 Steering Shaft Coupler: Service and Repair REMOVAL - STEERING COLUMN LOWER COUPLING NOTE: Before proceeding with this procedure, Refer to COLUMN - Service Precautions. 1. Place the steering wheel in the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation. 2. Inside the passenger compartment, remove the steering column coupling retainer pin, back off the pinch bolt nut, and remove the steering column coupling pinch bolt (the pinch bolt nut is caged to the coupling and is not removable). Separate the upper and lower steering column couplings. 3. Raise the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Page 5673 4. Release the locking tab on the wiring harness connector for the power steering fluid pressure switch before connector removal. Remove the wiring harness connector from the power steering fluid pressure switch. 5. Remove the drive-belt splash shield fasteners. Remove the shield. 6. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle. Remove the washer behind the strut from the torque strut bolt. 7. Remove the bolts mounting the engine torque strut in place, then remove the engine torque strut from the vehicle. NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be scribed on the body of the vehicle. Do this so that the crossmember can be relocated upon reinstallation against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Page 5674 8. Using an awl, scribe a line marking the location of where the front suspension crossmember is mounted against the body of the vehicle. 9. Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember. 10. Loosen and completely remove the two front bolts (one right and one left) attaching the front suspension crossmember to the frame rails of vehicle. The right side bolt can be viewed in the mounting bolt figure. The left side bolt is located in the same location on the other side of the vehicle. 11. Loosen the two rear bolts (one right and one left) attaching the front suspension crossmember and lower control arms to the body of the vehicle until they release from the threaded tapping plates in the body of the vehicle. Do not completely remove the rear bolts because they are designed to disengage from the body threads yet stay within the lower control arm rear isolator bushing. This allows the lower control arm to stay in place on the crossmember. The right side bolt can be viewed in the mounting bolt figure. The left side bolt is located in the same location on the other side of the vehicle. CAUTION: Lower the steering gear slowly, paying special attention to the power steering fluid hoses coming down from the power steering pump. Do not strain or over extend the hoses coming to the gear. Damage to the hoses or connecting hardware could occur. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Page 5675 12. Lower the front suspension crossmember using the transmission jack enough to allow sufficient access to the steering column lower coupling. When lowering front suspension crossmember, do not let crossmember hang from lower control arms or power steering hoses. The weight should be supported by the transmission jack. 13. Remove the roll pin securing the steering column lower coupling to the power steering gear pinion shaft using a roll pin punch. Push the steering column lower coupling up and off of the power steering gear pinion shaft. INSTALLATION - STEERING COLUMN LOWER COUPLING NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Push the column end of the steering column lower coupling partway up through its hole in the dash panel, then match the flat on the inside of the steering column lower coupling to the flat on the power steering gear pinion shaft and slide the coupling onto the top of the pinion shaft. Align the roll pin hole in the coupling with the groove in the pinion shaft and install the roll pin through the coupling until it is centered. 2. Center the power steering gear rack in its travel. 3. Using the transmission jack, raise the front suspension crossmember and power steering gear until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the steering column lower coupling up through its hole in the dash panel. 4. Start the two rear crossmember mounting bolts into the tapping plates mounted in the body. The right side bolt can be viewed in the mounting bolt figure. The left side bolt is located in the same location on the other side of the vehicle. Next, install the two front mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all four mounting bolts to a approximately 2 Nm (20 inch lbs.) to hold the front suspension crossmember in position. NOTE: When reinstalling the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Page 5676 5. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle. Once the front suspension crossmember is correctly positioned, tighten the rear two crossmember mounting bolts to a torque of 203 Nm (150 ft. lbs.), then tighten the front two crossmember mounting bolts to a torque of 142 Nm (105 ft. lbs.). 6. Install the engine torque strut and mounting bolts. To properly align and tighten the torque strut, Refer to TORQUE STRUT - ADJUSTMENTS. 7. Install the washer on the end of the stud extending from the torque strut bolt. 8. Install the pencil strut to the right front corner of the crossmember and body of the vehicle. Tighten the pencil strut nuts to a torque of 58 Nm (43 ft. lbs.). 9. Install the drive-belt splash shield and fasteners. 10. Reconnect the wiring harness connector to the power steering fluid pressure switch. Be sure the locking tab on the wiring harness connector is securely latched. 11. Lower the vehicle to ground level. 12. Install the dash-to-lower coupling seal in place over the lower coupling's plastic collar. NOTE: Verify that grease is present on the lip of the dash-to-coupling seal where it contacts the coupling's plastic collar. 13. Inside the passenger compartment, position the steering column in the full tilt-up position and secure the tilt lever, then reconnect the steering column lower coupling to the steering column upper coupling. Install the coupling pinch bolt and tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.). Install the pinch bolt retainer pin. 14. Remove the steering wheel holder. 15. While looking under the instrument panel at the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does not squeak against the dash-to-coupling seal. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Steering Wheel Retaining Screw .............................................................................................................................................................. 54 Nm (40 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 5680 Steering Wheel: Service Precautions 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. WARNING: ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 2. Disconnect and isolate the battery negative cable. 3. Remove the two mounting screws, one on each side of steering wheel, attaching the driver airbag to the steering wheel. 4. Lay the driver airbag back away from the center of the steering wheel. Disconnect the airbag squib and horn switch wiring connectors from the rear of the airbag. Remove the driver airbag from the steering wheel. 5. If equipped with speed control, disconnect the wiring connector from the speed control switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 5681 6. Holding the steering wheel firmly in place, remove the steering wheel retaining screw from the steering column shaft. CAUTION: When installing a wheel puller on the steering wheel, be sure the puller bolts are fully seated in the threaded holes on the steering wheel. If the bolts are not fully seated in the threaded holes, the threads may be stripped out of the steering wheel when attempting to remove the steering wheel. Also, thread the retaining nut back on the end of the shaft until it is flush with the shaft end to avoid damage to the shaft threads by the wheel puller. 7. Install a steering wheel puller on the steering wheel. CAUTION: Do not bump or hammer on steering wheel or steering column shaft when removing steering wheel from steering column. 8. While holding the steering wheel firmly in the STRAIGHT-AHEAD position, remove steering wheel from the steering column shaft using the puller. While removing the steering wheel, take care to feed the wires gently through the holes in the steering wheel. 9. If equipped with speed control, remove the speed control switch. INSTALLATION 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. 1. Confirm that: a. The front wheels are positioned straight ahead. b. The turn signal stalk is in the neutral position. 2. If equipped with speed control, install the speed control switch on the steering wheel. CAUTION: Do not install the steering wheel onto the shaft of the steering column by driving it onto the shaft. 3. Feed the clockspring wiring leads through the hole in the steering wheel. Align the steering wheel's wide mounting spline with the steering column shaft missing spline area and push the wheel onto the shaft. Make sure the clockspring squares up with the back of the wheel and does not bind. 4. Install the steering wheel retaining screw and tighten it until the steering wheel is fully installed on shaft. Tighten the retaining screw to a torque of 54.2 Nm (40 ft. lbs.). 5. If equipped with speed control, connect the wiring lead from the clockspring to the speed control switch on the steering wheel. 6. Position the driver airbag near the steering wheel. Connect the horn switch wiring lead to the connector on the back of the airbag. 7. Install the airbag squib wiring lead from the clockspring into the connector on the back of the driver airbag. Be sure the wiring connector is securely latched into the airbag connector. CAUTION: The fasteners originally used for the airbag components are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace it with only the correct fastener listed in the parts book. 8. Install the driver airbag into the center of the steering wheel. Align the airbag mounting holes with the bolt holes in the steering wheel. Install only the two original or identical replacement airbag module mounting screws. Tighten the two driver airbag attaching bolts to a torque of 10 Nm (90 inch lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE AT THIS TIME. REFER TO RESTRAINTS - DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Front Tie Rod Adjusting Jam Nut .................................................................................................................. ................................................ 75 Nm (55 ft. lbs.) Tie Rod End Steering Knuckle Nut ...................................................................................................................................................... 54 Nm (40 ft. lbs.) Steering Tie Rod Steering Arm Nut ................................................................................................................... ................................................. 55 Nm (40 ft. lbs.) Tie Rod Jam Nut .................................................. ................................................................................................................................. 75 Nm (55 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5686 Tie Rod End: Service and Repair TIE ROD OUTER REMOVAL 1. Raise the vehicle. 2. Remove the tire and wheel assembly from the vehicle. 3. Loosen tie rod jam nut. Thread the jam nut far enough up the inner tie rod to pull the collar away from the outer tie rod end. Pull the collar off the end of the outer tie rod. 4. Remove the nut attaching the outer tie rod end to steering knuckle. Remove the nut by holding the tie rod stud stationary while loosening and removing the nut with a wrench. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5687 5. Remove the outer tie rod from the steering knuckle using Remover, Special Tool MB991113. 6. Remove the tie rod heat shield. 7. Remove the outer tie rod from the inner tie rod by unthreading it. INSTALLATION 1. Install the jam nut on the inner tie rod threads if it is not already installed. NOTE: Be sure the collar is installed on the inner tie rod with the flat end of the collar against jam nut and the open end of the collar facing the outer tie rod end. 2. Install the collar on the inner tie rod. 3. Thread the outer tie rod onto the inner tie rod. 4. Position the collar around the end of the outer tie rod. 5. Thread the jam nut down the inner tie rod far enough to hold the collar in place on the outer tie rod. Do not tighten the jam nut. 6. Place the tie rod heat shield on the knuckle's steering arm, aligning the hole in the shield with the hole in the knuckle and the tangs on the outside of the shield with the outside configuration of the steering arm. The shield should now be facing outboard, away from the power steering gear and tie rod. 7. Attach the outer tie rod end to the steering knuckle. 8. Start the attaching nut onto the stud of the outer tie rod. 9. While holding the stud of the tie rod stationary with a wrench, tighten the attaching nut. 10. Using a crowfoot wrench attached to a torque wrench, tighten the attaching nut to 75 Nm (55 ft. lbs.). 11. Install the tire and wheel assembly. Tighten wheel nut to a torque of 135 Nm (100 ft. lbs.). 12. Lower the vehicle. 13. Adjust the front toe setting on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5688 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Front Ball Joint Stud Pinch Bolt Nut .............................................................................................................................................................. 95 Nm (70 ft. lbs.) For Ball Joint wear limit refer to Testing and Inspection, DIAGNOSIS AND TESTING - BALL JOINT. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5693 Ball Joint: Testing and Inspection DIAGNOSIS AND TESTING - BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the headless grease fitting as shown. With no mechanical assistance or added force, attempt to move the grease fitting. If the ball joint is worn, the grease fitting will move. If movement is noted, replace the ball joint. CAUTION: No attempt should be made to service the headless grease fitting on the ball joint. It has been purposely snapped off by the manufacturer to avoid over-greasing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint DISASSEMBLY - LOWER CONTROL ARM (BALL JOINT) NOTE: The removal and installation of the lower ball joint from the lower control arm is to be done with the lower control arm removed from the vehicle. 1. Using a screwdriver or other suitable tool, pry the seal boot off of the ball joint. 2. Position the Receiver, Special Tool 6908-2, on a hydraulic press to support the lower control arm. Place the control arm on top of Tool 6908-2 so that the bottom of the ball joint sets into the Receiver cup. 3. Place the larger end of the Adapter, Special Tool 6804, on top of the ball joint as shown. 4. Using the hydraulic press, press the ball joint completely out of the lower control arm, into the receiver. 5. Remove the tools, ball joint and arm from the hydraulic press. ASSEMBLY - LOWER CONTROL ARM (BALL JOINT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5696 CAUTION: When installing a ball joint in its mounting hole in the lower control arm, position the ball joint so the notch in the ball joint stud is facing the lower control arm front isolator bushing. This will ease assembly of the ball joint to the steering knuckle when the installation of the pinch bolt is attempted. 1. By hand, position ball joint into it's bore on the lower control arm. To avoid binding upon installation, be sure the ball joint is not cocked in the bore. 2. Position the Installer, Special Tool 6758, on a hydraulic press to support the lower control arm. Place the control arm on top of Tool 6758 in the upside-down position, aligning the ball joint stud squarely with the Installer's cup. 3. Place the larger end of the Adapter, Special Tool 6804, on top of the ball joint as shown. 4. Using the hydraulic press, press the ball joint into the lower control arm until the shoulder on the ball joint bottoms against the lower control arm ball joint bore. Do not apply excessive pressure against ball joint and lower control arm once the ball joint bottoms. 5. Remove the tools and arm from the hydraulic press. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5697 CAUTION: When installing the sealing boot on the ball joint, position the upward lip on the outside perimeter of the seal boot outward, away from the control arm once installed. It is there to help shield heat from the sealing boot. 6. Place a new ball joint seal boot over the ball joint stud. The upward lip located on the outside perimeter of the seal boot must point outward away from the control arm once installed. Start the sealing boot over the sides of the ball joint by hand. 7. Position the Installer, Special Tool 6758, over the sealing boot outer diameter as shown. By hand, apply pressure to the top of the Installer until the seal boot is pressed squarely down against the top surface of lower control arm. 8. Remove the tool. 9. If not already installed, install standard zirc-type grease fitting in ball joint. CAUTION: It is important to lubricate the ball joint before installation of steering knuckle to allow proper venting when the seal is filled. If the ball joint is lubricated after installation to knuckle, damage to the seal can occur. 10. Using a hand-operated pump grease gun, fill the ball joint seal boot with Mopar Multi-Mileage Lube or equivalent until grease pushes out past ball joint stem. Wipe off overfill. 11. Remove standard zirc-type grease fitting and install headless grease fitting from original ball joint to prevent future lubricating. See above Caution. Be sure to properly clean headless grease fitting prior to installation. 12. Install the lower control arm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5698 Ball Joint: Service and Repair Lower Ball Joint Seal Boot REMOVAL 1. Remove steering knuckle from vehicle. 2. Using a screwdriver or other suitable tool, pry seal boot off of ball joint. INSTALLATION 1. Wipe off used grease around ball joint stem. CAUTION: When installing the sealing boot on the ball joint, position the upward lip on the seal boot outside perimeter outward, away from the control arm once installed. It is there to help shield heat from the sealing boot. 2. Place NEW ball joint seal boot over ball joint stem. Upward lip located on outside perimeter of seal boot must point outward, away from control arm once installed. 3. By hand, start sealing boot over sides of the ball joint. 4. Position Installer, Special Tool 6758, over sealing boot outer diameter as shown. By hand, apply pressure to top of Installer until seal boot is pressed squarely down against top surface of lower control arm. 5. Remove tool. 6. Remove headless grease fitting on ball joint and replace it with standard zirc-type grease fitting. Do not discard headless grease fitting. CAUTION: It is important to lubricate the ball joint before installation of steering knuckle to allow proper venting when the seal is filled. If the ball joint is lubricated after installation to knuckle, damage to the seal can occur. 7. Using a hand operated pump grease gun, fill the ball joint seal boot with Mopar Multi-Mileage Lube or equivalent until grease pushes out past ball joint stem. Wipe off overfill. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5699 8. Remove standard zirc-type grease fitting and reinstall headless grease fitting on ball joint to prevent future lubricating. See above caution. 9. Install steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair DISASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING) NOTE: The removal and installation of the rear isolator bushing from the lower control arm is only to be done with the lower control arm removed from the vehicle. NOTE: The front isolator bushing is not serviceable. 1. Install the Remover Receiver, Special Tool 8373-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Remover Driver, Special Tool 8373-2, on the tip of the Ball Joint Press screw-drive. 2. Place the lower control arm outer flange against the Receiver as shown. Tighten the screw-drive until the Driver contacts the outer circumference of the bushing evenly. Continue to tighten the screw-drive until the bushing is pressed completely out of the lower control arm. 3. Back off the screw-drive and remove the lower control arm and isolator bushing from the Receiver. 4. Remove the driver 8373-2 and receiver 8373-1 from the ball joint press C-4212F. ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING) 1. Back the ball joint press C-4212F set screw outward so it does not extend out into the cup area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 5704 2. Start the bushing in the lower control arm bushing bore by hand. Position the bushing so the voids in the rubber are aligned in relationship to the ball joint as shown. 3. Install the Receiver, Special Tool 6760, on the tip of the Ball Joint Press screw drive. 4. Place the lower control arm flange against the cup area of the ball joint press and tighten the screwdriver until the Receiver contacts the outer circumference of the bushing. Slowly tighten the screw-drive until the bushing bottoms in the lower control arm bushing bore. 5. Back off the Ball Joint Press screw-drive and remove the power steering gear from the press. 6. Install the lower control arm on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation Front Cross-Member: Description and Operation FRONT CROSSMEMBER DESCRIPTION The front suspension crossmember must be properly installed to achieve design camber, caster settings and wheel stagger. The crossmember can be installed out of position on the frame rails due to its design. Bolts and cage nuts hold the rear of the crossmember to the frame torque boxes. Bolts and J-nuts hold the front of the crossmember to the frame rails. No designed in locating device is used to position the crossmember in the vehicle. Before removing the crossmember mark the frame torque box around the rear mounting location to aid installation. A crossmember that is removed during service must be installed in the same position from which it was removed. To verify that crossmember is in the proper position, refer to the dimensions provided. Front end dimensions are gauged from the principal locating point (PLP) holes located under the frame torque boxes rearward of the front wheels. After removal and installation of the crossmember is performed, verify that front suspension alignment is within specifications. If camber, caster settings and thrust angle are not within specifications, loosen and reposition crossmember to bring suspension within specifications. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5709 Front Cross-Member: Service and Repair FRONT SUSPENSION CROSSMEMBER CAUTION: If the front suspension crossmember is being replaced due to collision damage, inspect the steering column lower coupling for damage. REMOVAL 1. Raise the vehicle. 2. Remove both front tire and wheel assemblies from the vehicle. Fig. 13 3. Remove both stabilizer bar links from the vehicle (Fig. 13). Remove each link by holding the upper retainer/nut with a wrench and turning the link bolt. 4. Remove the stabilizer bar cushion retainer bolts and retainers (Fig. 13), and remove the stabilizer bar with cushions attached from the vehicle. Fig. 14 5. Remove the nut and pinch bolt clamping each ball joint stud to the steering knuckle (Fig. 14). CAUTION: After removing the steering knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the steering knuckle outward at this point can separate the inner C/V joint on the driveshaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5710 NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. Fig. 15 6. Separate each ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle (Fig. 15). 7. Remove the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler and can be accessed from above. Allow the cooler to hang out of the way. 8. Using wire or cord, support and tie off the power steering gear to the underbody of the vehicle, so when the crossmember is lowered, the gear does not fall away being held to the vehicle by only the steering column coupler and the fluid hoses. Fig. 16 9. Loosen and remove the four bolts attaching the power steering gear to the front suspension cross-member (Fig. 16). Remove the power steering gear from the front suspension crossmember. 10. Remove the drive-belt splash shield fasteners. Remove the shield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5711 Fig. 17 11. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle (Fig. 17). Remove the washer behind the strut from the torque strut bolt. 12. Remove the bolts mounting the engine torque strut in place (Fig. 17), then remove the engine torque strut from the vehicle. NOTE: Before removing the front suspension cross-member from the vehicle, the location of the cross-member must be scribed on the body of the vehicle (Fig. 9). Do this so that the crossmember can be relocated upon reinstallation against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost. Fig. 18 13. Using an awl, scribe a line (Fig. 18) marking the location of where the front suspension crossmember is mounted against the body of the vehicle. 14. Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5712 Fig. 19 15. Loosen and completely remove the two front bolts (one right and one left) attaching the front suspension crossmember to the frame rails of vehicle. The right side bolt can be viewed in the mounting bolt figure (Fig. 19). The left side bolt is located in the same location on the other side of the vehicle. 16. Loosen the two rear bolts (one right and one left) attaching the front suspension crossmember and lower control arms to the body of the vehicle until they release from the threaded tapping plates in the body of the vehicle. Remove the rear bolts from the body of the vehicle, but do not completely remove the rear bolts because they are designed to disengage from the body threads yet stay within the lower control arm rear isolator bushing. This allows the lower control arm to stay in place on the crossmember. The right side bolt can be viewed in the mounting bolt figure (Fig. 19). The left side bolt is located in the same location on the other side of the vehicle. 17. Lower the front suspension crossmember. 18. Remove each lower control arm from the crossmember by removing the front pivot bolt. INSTALLATION CAUTION: If the front suspension crossmember is being replaced due to collision damage, inspect the steering column lower coupling for damage. 1. Install the lower control arms on the front suspension crossmember. Install the pivot bolts, but do not completely tighten them at this time. 2. Using the transmission jack, raise the front suspension crossmember and lower control arms until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the power steering gear into mounting position. 3. Start the two rear crossmember mounting bolts into the tapping plates mounted in the body. The right side bolt can be viewed in the mounting bolt figure (Fig. 19). The left side bolt is located in the same location on the other side of the vehicle. Next, install the two front mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all four mounting bolts to a approximately 2 N.m (20 in.lbs.) to hold the front suspension crossmember in position. NOTE: When reinstalling the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost. 4. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle (Fig. 18). Once the front suspension crossmember is correctly positioned, tighten the rear two crossmember mounting bolts to a torque of 203 N.m (150 ft.lbs.), then tighten the front two crossmember mounting bolts to a torque of 142 N.m (105 ft.lbs.). 5. Tighten the lower control arm front pivot bolts to a torque of 163 N.m (120 ft.lbs.). 6. Attach the steering gear to the front suspension crossmember (Fig. 16). Install the four power steering gear mounting bolts. Tighten the mounting bolts to a torque of 61 N.m (45 ft.lbs.). 7. Remove the wire or cord suspending the power steering gear to the underbody. 8. Install the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler. 9. Install each ball joint stud into the steering knuckle aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud. 10. Install a new ball joint stud pinch bolt and nut (Fig. 14). Tighten the nut to a torque of 95 N.m (70 ft.lbs.). 11. Install the engine torque strut and mounting bolts (Fig. 17). To properly align and tighten the torque strut, Refer to Engine Mount. 12. Install the washer on the end of the stud extending from the torque strut bolt (Fig. 17). 13. Install the pencil strut to the right front corner of the crossmember and body of the vehicle (Fig. 17). Tighten the pencil strut nuts to a torque of 58 N.m (43 ft.lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5713 14. Install the drive-belt splash shield and fasteners. Fig. 20 NOTE: Before installing the stabilizer bar, make sure the bar is not upside-down. The stabilizer bar must be installed with the curve on the outboard ends of the bar facing downward to clear the control arms once fully installed (Fig. 20). 15. First, place the stabilizer bar in position on the front suspension crossmember. The slits in each cushion must point toward the front of the vehicle and sit directly on top of the raised beads formed into the stamping on the crossmember. Next, install the cushion retainers, matching the raised beads formed into the cushion retainers to the grooves formed into the cushions. Install the cushion retainer bolts, but do not completely tighten them at this time. 16. Install both stabilizer bar links back on vehicle (Fig. 13). Start each stabilizer bar link bolt with bushing from the bottom, through the stabilizer bar , inner link bushings, lower control arm, and into the upper retainer/nut and bushing. Do not fully tighten the link assemblies at this time. 17. Install the tire and wheel assemblies back on vehicle. Tighten the wheel mounting nuts to 135 N.m (100 ft.lbs.) torque. 18. Lower the vehicle. NOTE: It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height. 19. Tighten each stabilizer bar link by holding the upper retainer/nut with a wrench and turning the link bolt. Tighten each link bolt to a torque of 23 N.m (200 in.lbs.). 20. Tighten the stabilizer bar cushion retainer bolts to a torque of 34 N.m (300 in.lbs.). 21. Check the front wheel alignment on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications FRONT STEERING KNUCKLE: Disc Brake Caliper Guide Bolts ................................................................................................................................................ 22 Nm (192 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5717 Front Steering Knuckle: Description and Operation DESCRIPTION - STEERING KNUCKLE The steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5718 bottom, and steering linkage on the trailing end. The steering knuckle also has two machined abutments (rails) on the leading end casting to support and align the front disc brake caliper. The knuckle supports the wheel bearing and hub. The wheel hub is pressed into a sealed-for-life wheel bearing that is pressed into the steering knuckle. A retainer plate also holds the bearing in place. The hub supports the driveshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a nut retainer and cotter pin. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub has five studs pressed into its flange. OPERATION - STEERING KNUCKLE The steering knuckle pivots with the strut assembly between the lower ball joint and the pivot bearing in the strut assembly. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub, wheel bearing and axle shaft. The hub and wheel bearing work together. The wheel bearing has internal bearings that allow the hub to rotate with the driveshaft and the tire and wheel assembly. The hub's five studs mount the tire and wheel to the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5719 Front Steering Knuckle: Testing and Inspection DIAGNOSIS AND TESTING - STEERING KNUCKLE 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5720 Front Steering Knuckle: Service and Repair REMOVAL - STEERING KNUCKLE NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Apply the brakes and hold in place. 2. Raise the vehicle. 3. Remove the front tire and wheel assembly. 4. Remove the cotter pin, lock nut and spring washer from the hub nut. 5. While the brakes are applied, loosen and remove the hub nut. 6. Release the brakes. 7. Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle. 8. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side) or bottom (left side) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide (on the knuckle) and rotor. 9. Hang the caliper out of the way using a wire hanger or cord. Do not support the caliper by letting it hang by the hydraulic hose. 10. Remove any retainer clips from the wheel mounting studs. Remove the brake rotor from the front hub. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5721 11. Remove the nut attaching the outer tie rod to the steering knuckle. To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 12. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB991113. 13. Remove the tie rod heat shield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5722 14. Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle. CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckles while removing the nuts, then tap the bolts out using a pin punch. 15. Remove the two bolts attaching the strut to the steering knuckle. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. 16. Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle. NOTE: Do not allow the driveshaft to hang by the inner ON joint; it must be supported to keep the joint from separating during this operation. 17. Pull the steering knuckle off the driveshaft outer C/V joint splines and remove the steering knuckle. NOTE: 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 wheel bearing, a new bearing must be installed in the steering knuckle. Installation of the new wheel bearing and hub must be done before installing the steering knuckle on the vehicle. 18. If the steering knuckle is to be replaced, the hub and wheel bearing must be removed. Do not reuse the wheel bearing. DISASSEMBLY- STEERING KNUCKLE (WHEEL BEARING AND HUB) NOTE: The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle. Removal of the wheel bearing from the steering knuckle must be done using the following procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5723 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. 2. Using Remover, Special Tool 41 50A, press one wheel mounting stud out of hub flange. Rotate the hub to align the removed wheel mounting stud with the notch in bearing retainer plate. Remove the wheel mounting stud from the hub. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5724 3. Rotate the hub so the hole in the hub that wheel mounting stud was removed from is facing away from brake caliper lower rail on steering knuckle. Install one half of the Bearing Splitter, Special Tool 1130, between the hub and the bearing retainer plate. NOTE: Align the threaded hole in this first half of the bearing splitter with the caliper rail on the steering knuckle. 4. Install the remaining pieces of Bearing Splitter, Special Tool 1130, on the steering knuckle. Hand tighten the nuts to hold bearing splitter in place on steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5725 5. Once the bearing splitter in fully installed, be sure the three bolts attaching the bearing retainer plate to steering knuckle are contacting the bearing splitter. The bearing retainer plate should not support the steering knuckle or contact the bearing splitter. 6. Place the steering knuckle in an arbor press supported by the bearing splitter as shown. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5726 7. Position Driver, Special Tool 6644-2, on the small end of the hub. Using the arbor press, remove the hub from the wheel bearing. The outer bearing race will normally come out of the wheel bearing when the hub is pressed out of the bearing. 8. Remove the bearing splitter from the steering knuckle. 9. Remove the three bolts mounting the bearing retainer plate to the steering knuckle. Remove the bearing retainer plate from the steering knuckle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5727 10. Place the steering knuckle back in the arbor press supported by press blocks as shown. The press blocks must not obstruct the bore in the steering knuckle so the wheel bearing can be pressed out of the steering knuckle. Place Bearing Driver, Special Tool MB-990799 on the outer race of wheel bearing. Press the wheel bearing out of the steering knuckle. 11. Install Bearing Splitter, Special Tool 1130, on the hub. The bearing splitter is to be installed on the hub so it is between the flange of the hub and the outer bearing race on the hub. Place the hub, bearing race and bearing splitter in an arbor press as shown. Place Driver, Special Tool 6644-2 on end of hub. Press the hub out of the outer bearing race. ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB) NOTE: The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle. 1. Wipe the empty bore of the steering knuckle clean of any grease or dirt with a clean, dry shop towel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5728 2. Place the new wheel bearing into the bore of the steering knuckle. Be sure the wheel bearing is placed squarely into the bore. Place the steering knuckle in an arbor press with Receiver, Special Tool C-4698-2, supporting the steering knuckle. Place Driver, Special Tool 5052, on the outer race of the wheel bearing. Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle. Remove the knuckle from the press. NOTE: Only the original or identical replacement bolts are to be used to mount the bearing retainer plate to the steering knuckle. 3. Install the bearing retainer plate on the steering knuckle. Install the three bearing retainer mounting bolts. Tighten the bearing retainer plate mounting bolts to a torque of 28 Nm (250 inch lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5729 4. Place the previously removed wheel mounting stud back into the hub flange. Place the hub in the arbor press supported by Special Tool C-4698-1. Press wheel mounting stud into hub flange until it is fully seated against the back side on the hub flange. Remove the hub from the press. 5. Place the steering knuckle with the wheel bearing installed back in the arbor press with Receiver, Special Tool MB-990799 supporting the inner race of the wheel bearing as shown. Place the hub in wheel bearing making sure it is square with the bearing inner race. Press the hub into the wheel bearing until it is fully bottomed in the wheel bearing. Remove the knuckle from the press. 6. Install the steering knuckle assembly on the vehicle. INSTALLATION - STEERING KNUCKLE 1. If the steering knuckle is being replaced and the wheel bearing and hub must be installed. Do not reuse the old wheel bearing. 2. Slide the hub of the steering knuckle onto the splines on the driveshaft C/V joint. 3. Install the steering knuckle onto the ball joint stud aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud. 4. Install a new ball joint stud pinch bolt and nut. Tighten the nut to a torque of 95 Nm (70 ft. lbs.). CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. 5. Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes. Install the two attaching bolts. The bolts should be installed with so that the nuts face towards the front of the vehicle once installed. Install the nuts. Holding the bolts in place tighten the nuts to a torque of 53 Nm (40 ft. lbs.) plus an additional 90° turn after the specified torque is met. 6. Place the tie rod heat shield on the steering knuckle arm so that the shield is positioned straight away from the steering gear and tie rod end once Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5730 installed. Align the hole in the shield with the hole in the steering knuckle arm. 7. Install the outer tie rod ball stud into the hole in the steering knuckle arm. Start the tie rod attaching nut onto the stud. Hold the tie rod end stud with a wrench while tightening the nut with a standard wrench or crowfoot wrench. To fully tighten the nut to specifications, use a crowfoot wrench on a torque wrench to turn the nut, and a wrench on the stud. Tighten the nut to a torque of 55 Nm (40 ft. lbs.). 8. Install the brake rotor on the hub. 9. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 10. Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 11. Clean all foreign matter from the threads of the driveshaft outer C/V joint. 12. Install the hub nut in the end of the driveshaft and snug it. 13. Have a helper apply the brakes. With vehicle brakes applied to keep brake rotor and hub from turning, tighten the hub nut to a torque of 244 Nm (180 ft. lbs.). 14. Install the spring washer, lock nut and cotter pin on the hub nut. Wrap the cotter pin ends tightly around the lock nut. 15. Install the tire and wheel assembly. Install the wheel mounting nuts and tighten them to a torque of 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Set front toe on the vehicle to specification. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Testing and Inspection Radius Arm: Testing and Inspection TENSION STRUT DESCRIPTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Testing and Inspection > Page 5734 The tension strut controls the fore-and-aft movement of the rear knuckle. There is one tension strut per side of the rear suspension. The leading end of the tension strut attaches to the frame rail while the trailing end of the strut attaches to the lower end of the rear knuckle. The tension strut is isolated from the rest of the rear suspension through the use of rubber bushings located at each end. The rear bushings (bayonet type) can be serviced separately, the front bushings (spool type) cannot. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Testing and Inspection > Page 5735 Radius Arm: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Remove the rear wheel and tire assembly from the vehicle. 3. Disconnect the tension strut from the knuckle. To do this, first hold the tension strut from turning by using a wrench on the flat on the tension strut and then remove the nut from the rear of the tension strut. Next, remove the tension strut retainer, then the rear tension strut bayonet bushing from the tension strut. 4. Remove the nuts attaching the parking brake cable bracket to the studs on the tension strut mounting bolt at the frame. Remove the parking brake cable from the studs. 5. Remove the two mounting bolts holding the tension bolts to the frame, then remove the tension strut from the vehicle. 6. Remove the forward bayonet bushing and retainer from the tension strut. INSPECTION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Testing and Inspection > Page 5736 Inspect the tension strut. Look for signs of contact with any object that 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. Inspect the tension strut front (spool type) bushing, and rear (bayonet type) bushings and retainers for signs of deterioration or damage. If the front Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Testing and Inspection > Page 5737 bushing is damaged or shows signs of deterioration, the tension strut must be replaced. The front bushing cannot be replaced separately. If the rear bushings are deteriorated or damaged, or the retainers are damaged, replacement is necessary. The bushings and retainers can be replaced separately from the tension strut. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Install the forward retainer and a bayonet bushing on the tension strut trailing end. Be sure the stepped area of the bushing is installed to face the knuckle. 2. To install the knuckle on the tension, first stick the trailing end through the hole in the lower end of the knuckle, seating the bayonet bushing squarely against the hole. Next, raise the end of the tension strut with the spool bushing into its mounting position on the frame. Install the mounting bolts securing the tension strut to the frame. 3. Tighten the two mounting bolts at the frame to a torque of 95 Nm (70 ft. lbs.). 4. Place the parking brake cable routing bracket on the studs of the tension strut mounting bolts and install the nuts securing it in place. Tighten the nuts to a torque of 28 Nm (250 inch lbs.). 5. Install the rear bayonet bushing on the tension strut. Be sure the stepped area of the bushing is squarely seated into the hole in the knuckle. 6. Install the rear tension strut retainer, then the nut. To completely install the nut, place a wrench on the flat formed into the tension strut and tighten the nut. Tighten the nut to a torque of 95 Nm (70 ft. lbs.). 7. Install the tire and wheel assembly. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence, this time, to full specified torque of 135 Nm (100 ft. lbs.). 8. Lower the vehicle to ground level. 9. Set the rear toe on the vehicle to specification as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications Rear Knuckle: Specifications REAR KNUCKLE: Brake Support Plate Mounting Bolts .............................................................................................................................................. 75 Nm (55 ft. lbs.) Disc Brake Adapter Mounting Bolts .............................................................................................................................................. 75 Nm (55 ft. lbs.) LATERAL ARM: Nut At Knuckle ..................................................................................................................................... .......................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5741 Rear Knuckle: Description and Operation DESCRIPTION A forged rear knuckle bolts to each rear strut assembly. The rear knuckle's spindle supports the rear hub and bearing. Together they support the rear Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5742 tire and wheel. The movement of the rear knuckle is controlled laterally using two lateral arms attached to the knuckle. Fore and aft movement of the knuckle is controlled by using a tension strut. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5743 Rear Knuckle: Testing and Inspection DIAGNOSIS AND TESTING - KNUCKLE (REAR) The rear knuckle is not a repairable component of the rear suspension. Upon visual inspection, if it is determined that the knuckle is cracked, bent or broken, 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5744 Rear Knuckle: Service and Repair REMOVAL - KNUCKLE (REAR) NOTE: Before proceeding with this procedure, Refer to Service PrecautionsService Precautions. 1. Raise the vehicle. 2. Remove the rear wheel and tire assembly from the vehicle. 3. If the vehicle is equipped with rear drum brakes, remove the screw securing the brake hose bracket to the rear of the strut assembly. 4. If the vehicle is equipped with the antilock brake system (ABS), remove the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly. 5. If the vehicle is equipped with rear drum brakes, remove any retainer clips from the wheel mounting studs, then pull the brake drum off the hub and bearing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5745 6. If the vehicle is equipped with rear disc brakes, perform the following: ^ Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle. ^ Remove the disc brake caliper from the knuckle and brake rotor. ^ Hang the caliper out of the way using a wire hanger or cord. Do not support the caliper by letting it hang by the hydraulic hose. ^ Remove any retainer clips from the wheel mounting studs, then pull the brake rotor off the hub and bearing. 7. Remove the dust cap from the hub and bearing assembly. 8. Remove the retaining nut, then the hub and bearing from the knuckle's spindle. 9. If vehicle is equipped with rear drum brakes, remove the four bolts attaching the rear brake support plate to the knuckle. Next, remove the brake support plate, brake shoes and wheel cylinder as an assembly from the rear knuckle, then hang it out of the way using a wire hanger or cord. Do not overextend the brake hose when being hung. It is not necessary to remove the brake hose from the wheel cylinder when removing the support plate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5746 10. If the vehicle is equipped with rear disc brakes, remove the four bolts mounting the disc brake adapter to the rear knuckle. Next, remove the adapter, rotor shield, parking brake shoes and parking brake cable as an assembly from the knuckle, then hang it out of the way using a wire hanger or cord. CAUTION: The strut-to-knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckle while removing the nuts, then tap the bolts out using a pin punch. 11. Loosen, but do not completely remove the two nuts and bolts attaching the rear knuckle to the strut. 12. Remove the nuts and bolt attaching the rear knuckle to the lateral arms. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 5747 13. Disconnect the tension strut from the knuckle. To do this, first hold the tension strut from turning by using a wrench on the flat on the tension strut and then remove the nut from the rear of the tension strut. Next, remove the tension strut retainer, then the rear tension strut bayonet bushing from the tension strut. 14. Remove the two nuts and bolts attaching the rear knuckle to the strut. Tap the bolts from the knuckle using a pin punch. 15. Remove the knuckle. INSTALLATION - KNUCKLE (REAR) NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. To install the knuckle on the vehicle, first align the hole in the lower end of the rear knuckle with the forward bayonet bushing on the tension strut. Be sure the stepped area of the bushing is squarely seated into the hole in the knuckle. Next, Rotate the knuckle until the upper mounting holes in the knuckle is aligned with the holes in the strut's clevis bracket. CAUTION: The strut-to-knuckle attaching bolts are serrated and must not be turned during installation. Once installed, hold the bolts stationary in the steering knuckle while installing and tightening the nuts. 2. Install the two bolts attaching the strut to the rear knuckle from the front side. Install the nuts on the bolts. Tighten the two nuts to a torque of 88 Nm (65 ft. lbs.). 3. Align the lateral arms with the hole in the center of the knuckle. Install the bolt attaching the arms to the knuckle. When installing the bolt, start it from the front side. Install the nut, but do not completely tighten it at this time. The nut will need to be tightened when the vehicle is at curb height. 4. Install the rear bayonet bushing on the tension strut. Be sure the stepped area of the bushing is squarely seated into the hole in the knuckle. 5. Install the rear tension strut retainer, then the nut. To completely install the nut, place a wrench on the flat formed into the tension strut and tighten the nut. Tighten the nut to a torque of 95 Nm (70 ft. lbs.). 6. If vehicle is equipped with rear drum brakes, install the brake support plate on the knuckle and attach it using it's four mounting bolts. Tighten the mounting bolts to a torque of 75 Nm (55 ft. lbs.). 7. If the vehicle is equipped with rear disc brakes, install the disc brake adapter on the knuckle and attach it using it's four mounting bolts. Tighten the mounting bolts to a torque of 75 Nm (55 ft. lbs.). 8. Install the hub and bearing on the knuckle's spindle, then install a new retaining nut. Do not reuse the original nut. Tighten the nut to a torque of 217 Nm (160 ft. lbs.). 9. Install the dust cap on the end of the hub and bearing. 10. If the vehicle is equipped with rear disc brakes, install the brake rotor and disc brake caliper on the knuckle. Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 11. If the vehicle is equipped with rear drum brakes, install the screw securing the brake hose bracket to the rear of the strut assembly. Tighten the screw to a torque of 31 Nm (275 inch lbs.). 12. If the vehicle is equipped with the antilock brake system (ABS), install the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly. Tighten the mounting screw to a torque of 13 Nm (120 inch lbs.). 13. Install the tire and wheel assembly. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence, this time, to full specified torque of 135 Nm (100 ft. lbs.). 14. Lower the vehicle to ground level. 15. Tighten the lateral arm-to-knuckle mounting bolt nut to a torque of 95 Nm (70 ft. lbs.). 16. Set the rear toe on the vehicle to specification if necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications Stabilizer Bar: Specifications Front STABILIZER BAR: Cushion Retainer Bolts .............................................................................................................................................................. 28 Nm (250 inch lbs.) Link Nut ............................................................................................................ ........................................................................ 31 Nm (275 inch lbs.) Rear STABILIZER BAR: Cushion Retainer Bolts .............................................................................................................................................................. 34 Nm (300 inch lbs.) Link Bolt Nut ..................................................................................................... ....................................................................... 23 Nm (200 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front Stabilizer Bar: Description and Operation Front DESCRIPTION The stabilizer bar helps control vehicle body roll. Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel of the vehicle to stabilize body roll. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 5753 The stabilizer bar interconnects both front lower control arms of the vehicle and is attached to the front suspension crossmember. Attachment of the stabilizer bar to the front suspension crossmember is through 2 rubber-isolator cushion and retainers. The stabilizer bar attachment to the lower control arm is done by utilizing an isolated stabilizer bar link at each arm. All components of the stabilizer bar are serviceable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 5754 Stabilizer Bar: Description and Operation Rear DESCRIPTION Some versions of this vehicle are equipped with a rear stabilizer bar. The stabilizer bar interconnects both rear strut assemblies and is attached to the rear frame rails of the vehicle. The rear stabilizer bar allows jounce and rebound movements affecting one wheel to be partially transmitted to the opposite wheel of the vehicle to stabilize body roll. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 5755 Attachment of the stabilizer bar to the rear frame rails of the vehicle is through two rubber-isolator cushions and retainers. The stabilizer bar attachment to each strut assembly is done utilizing a rubber isolated stabilizer bar link. All parts of the stabilizer bar are serviceable, and the stabilizer bar to frame rail isolator cushions are split for easy removal and installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Testing and Inspection > Front Stabilizer Bar: Testing and Inspection Front DIAGNOSIS AND TESTING - STABILIZER BAR (FRONT) Inspect for broken, cracked or distorted stabilizer bar cushions and retainers. Inspect for worn or damaged stabilizer bar links. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Testing and Inspection > Front > Page 5758 Stabilizer Bar: Testing and Inspection Rear DIAGNOSIS AND TESTING - STABILIZER BAR (REAR) Inspect the stabilizer bar. Look for damage or bending. If damage is evident, the bar must be replaced. Inspect for broken, cracked or distorted stabilizer bar cushions and cushion retainers. The horizontal slit at the front of each cushion is supposed to be there. If damage is evident, the cushions can be replaced separately from the stabilizer bar utilizing the horizontal slit. Inspect the stabilizer bar links that attach the stabilizer bar to each rear strut. Look for damage or deterioration of the bushings on the ends of each link. Inspect the stabilizer bar link to ensure it is not bent or broken. If any of these conditions are present, the stabilizer bar link must be replaced. The links can be replaced separately from the stabilizer bar. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions . 1. Raise the vehicle. 2. Remove both stabilizer bar links from the vehicle. Remove each link by holding the upper retainer/nut with a wrench and turning the link bolt. 3. Remove the stabilizer bar cushion retainer bolts and retainers, and remove the stabilizer bar with cushions attached from the vehicle. 4. To remove the cushions from the stabilizer bar, peel back each cushion at the slit and roll it off the bar. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions NOTE: Before stabilizer bar installation, inspect the cushions and links for excessive wear, cracks, damage and distortion. Replace any pieces failing inspection. 1. If removed, install the stabilizer bar cushions on the stabilizer bar utilizing the slit in each cushion. Position the cushions at each end of the bar's straight beam, just before it begins to curve. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5761 NOTE: Before installing the stabilizer bar, make sure the bar is not upside-down. The stabilizer bar must be installed with the curve on the outboard ends of the bar facing downward to clear the control arms once fully installed. 2. First, place the stabilizer bar in position on the front suspension crossmember. The slits in each cushion must point toward the front of the vehicle and sit directly on top of the raised beads formed into the stamping on the crossmember. Next, install the cushion retainers, matching the raised beads formed into the cushion retainers to the grooves formed into the cushions. Install the cushion retainer bolts, but do not completely tighten them at this time. 3. Install both stabilizer bar links back on vehicle. Start each stabilizer bar link bolt with bushing from the bottom, through the stabilizer bar, inner link bushings, lower control arm, and into the upper retainer/nut and bushing. Do not fully tighten the link assemblies at this time. 4. Lower the vehicle. NOTE: It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height. 5. Tighten each stabilizer bar link by holding the upper retainer/nut with a wrench and turning the link bolt. Tighten each link bolt to a torque of 31 Nm (275 inch lbs.). 6. Tighten the stabilizer bar cushion retainer bolts to a torque of 28 Nm (250 inch lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5762 Stabilizer Bar: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions . 1. Raise the vehicle. 2. Remove both rear wheel and tire assemblies from the vehicle. 3. Remove the nut from the end of each rear stabilizer bar link bolt. Pull the bolt out through the top of the link and remove the link from each end of the stabilizer bar. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5763 4. Remove the two bolts securing each of the two cushion retainers to the frame rails, then remove the cushion retainers, cushions and stabilizer bar from the vehicle as an assembly. 5. Pull the cushion retainers off the cushions. 6. The cushions can be removed from the bar by utilizing the pre-formed slit in each cushion and peeling it off the bar. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5764 INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions . 1. Install the cushions on the stabilizer bar by opening the slit in the cushion and wrapping the cushion around the bar. When installed properly, the slit in the cushion should face in the same direction as the ends of the stabilizer bar, or toward the front of the car once the bar is installed. The flat side of each cushion should face upward. 2. Install the retainers on the cushions, matching the contour of each retainer with its cushion. 3. Install the stabilizer bar, cushions and retainers on the car as an assembly. The dipped area in the center of the bar must face down to clear the well in the luggage compartment. 4. Install two bolts in each cushion retainer and secure the stabilizer bar to the frame of the vehicle. Do not completely install the bolts at this time. 5. Reinstall each stabilizer bar link: a. Place the link center sleeve and bushings between the eye in the end of the stabilizer bar and the link mounting bracket on the strut. b. Start the stabilizer bar link bolt with bushing from the top, down through the stabilizer bar, inner link bushings and sleeve, and strut link mounting bracket. c. Install a lower bushing, then the nut. Do not tighten the nut at this time. 6. Install both tire and wheel assemblies on the vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence, this time, to full specified torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle to ground level or curb height. 8. Tighten the rear stabilizer bar cushion retainer bolts to a torque of 34 Nm (300 inch lbs.). 9. Tighten the stabilizer bar link nuts to a torque of 23 Nm (200 inch lbs.). 10. Set the rear toe on the vehicle to specification if necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications FRONT STRUT ASSEMBLY: Tower Nuts .......................................................................................................................................... ...................................... 34 Nm (300 inch lbs.) Steering Knuckle Nuts ...................................................................................................................................... 54 Nm (40 ft. lbs.) + 90 degree Turn Strut Shaft Nut ................................................................................................ ................................................................................ 75 Nm (55 ft. lbs.) REAR STRUT ASSEMBLY: Tower Attaching Nuts .............................................................................................................................................................. 34 Nm (300 inch lbs.) Knuckle Attaching Bolts .................................................................................... ............................................................................. 88 Nm (65 ft. lbs.) Strut Assembly Shaft Nut ......... ...................................................................................................................................................... 75 Nm (55 ft. lbs.) Brake Hose Bracket Mounting Bolt .......................................................................................................................................... 31 Nm (275 inch lbs.) TENSION STRUT: Rear Nut .............................................................................................................................................. ........................................... 95 Nm (70 ft. lbs.) Frame Rail Bolts ........................................................ ..................................................................................................................... 95 Nm (70 ft. lbs.) Parking Brake Cable Nut ........................................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 DESCRIPTION - STRUT ASSEMBLY (FRONT) There are two different design struts available on this vehicle. A standard strut and an adjustable strut which is used on vehicles equipped with the ACR performance package. Both struts share common style components except that the ACR strut has no external jounce bumper. It is internal. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5770 A MacPherson type design strut assembly is used in place of the front suspension upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using 2 attaching bolts and nuts going through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the three threaded studs on the strut assemblies upper mount. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. The strut assembly includes the following components: ^ Strut shaft retaining nut ^ Upper mount (rubber isolated) ^ Upper spring seat and bearing ^ Dust shield ^ Jounce bumper ^ Coil spring ^ Lower spring isolator ^ Strut (damper) Each component is serviced by removing the strut assembly from the vehicle and disassembling it. The strut and front suspension of the vehicle is supported by coil springs positioned around the upper half of each strut. The springs are contained between the upper and the lower seats of the strut assembly. 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 of the strut assembly, if both springs are removed, mark the springs to ensure installation in its original position. NOTE: If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. The adjustable ACR strut has a knob on the bottom. It is there to adjust the suspension firmness. Although the strut shaft is much thicker on ACR struts, the same upper mount and retaining nut can be used. OPERATION - STRUT ASSEMBLY (FRONT) The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5771 Suspension Strut / Shock Absorber: Description and Operation Rear DESCRIPTION - STRUT ASSEMBLY (REAR) There are two different design struts available on this vehicle. A standard strut and an adjustable strut which is used on vehicles equipped with the ACR performance package. Both struts share common style components except that the ACR strut has no external jounce bumper. It is internal. The rear strut assemblies support the weight of the vehicle using coil springs positioned around 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. 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 with prevailing torque nuts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5772 The rear strut assembly includes the following components: ^ Strut shaft retaining nut ^ Upper mount (rubber isolated) ^ Dust shield Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5773 ^ Jounce bumper ^ Coil spring ^ Lower spring isolator ^ Strut (damper) Any component in need of service requires removal of the strut assembly from the vehicle and disassembly of it. Rear coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure the spring needing replacement is replaced with a spring meeting the correct load rating for the vehicle with its specific options. The adjustable ACR strut has a knob on the bottom. It is there to adjust the suspension firmness. Although the strut shaft is much thicker on ACR struts, the same upper mount and retaining nut can be used. OPERATION - STRUT ASSEMBLY (REAR) The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT) Inspect the strut assembly for the following conditions: - Inspect for a damaged or broken coil spring. - Inspect for a torn or damaged strut assembly dust shield. - Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end of the strut 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 shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly. - Lift the dust shield and inspect the jounce bumper for signs of damage or deterioration (non ACR vehicles only). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5776 - Inspect the clearance between the shock tower and the coil spring. Make sure no fasteners are protruding through the shock tower possibly contacting the coil spring and strut. 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. CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt or other metal fastener be installed into the shock tower to take the place of an original plastic clip. Also, do not drill holes into the front shock tower for the installation of any metal fasteners into the shock tower area indicated. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5777 Suspension Strut / Shock Absorber: Testing and Inspection Rear DIAGNOSIS AND TESTING - STRUT ASSEMBLY (REAR) Inspect the strut assembly for the following conditions: ^ Inspect for a damaged or broken coil spring. ^ Inspect for a torn or damaged strut assembly dust shield. ^ Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end of the strut 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 shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly. ^ Lift the dust shield and inspect the jounce bumper for signs of damage or deterioration. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front REMOVAL - STRUT ASSEMBLY (FRONT) NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel assembly from location on front of vehicle requiring strut removal. 3. If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. 4. Remove the screw securing the ground strap to the rear of the strut. 5. If the vehicle is equipped with Antilock brakes (ABS), remove the screw securing the ABS wheel speed sensor to the rear of the strut. CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckle while removing the nuts, then tap the bolts out using a pin punch. 6. Remove the two bolts attaching the strut to the steering knuckle. 7. Lower the vehicle just enough to open the hood, but without letting the tires touch the floor. 8. Remove the three nuts attaching the upper mount of the strut assembly to the vehicle's strut tower. 9. Remove the strut assembly from the vehicle. 10. For disassembly procedures, Refer to STRUT- DISASSEMBLY. DISASSEMBLY - STRUT ASSEMBLY (FRONT) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5780 The Strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. 1. If both struts are being serviced at the same time, mark the coil spring and strut assembly according to which side of the vehicle the strut was removed from, and which strut the coil spring was removed from. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5781 2. Position the strut assembly in the strut coil spring compressor following the manufacturers instructions. Set the lower hooks, then set the upper hooks. Position the strut clevis bracket straight outward away from the compressor. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed. WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 3. Compress the coil spring until all coil spring tension is removed from the upper mount. 4. Once the spring is sufficiently compressed, install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5782 5. Remove the upper mount from the strut shaft. 6. Remove the upper spring seat and bearing, along with the upper spring isolator as an assembly from the top of the coil spring by pulling them straight up. The upper spring isolator can be separated from the spring seat and bearing once removed from vehicle. 7. Remove the dust shield, then the jounce bumper from the strut shaft by pulling each straight up. 8. Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring. 9. Remove the lower spring isolator from the lower spring seat on the strut. NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with step 11. 10. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 11. Inspect the strut assembly components for the following and replace as necessary: - Inspect the strut for any condition of shaft binding over the full stroke of the shaft. - Inspect the jounce bumper for cracks and signs of deterioration (non-ACR vehicles only). - Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. - Check the upper spring seat and bearing for cracks and distortion. - Check for binding of the upper spring seat and bearing pivot bearing. - Inspect the dust shield for rips and deterioration. - Inspect the upper and lower spring isolators for material deterioration and distortion. ^ Inspect the coil spring for any sign of damage to the coating. ASSEMBLY - STRUT ASSEMBLY (FRONT) For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 3. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5783 1. Place the coil spring in the compressor following the manufacturers instructions. Before compressing the spring, rotate the spring so the end of the top coil is directly in the back as shown. 2. Slowly compress the coil spring until enough room is available for strut assembly reassembly. 3. Install the lower spring isolator on the lower spring seat of the strut. 4. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. Rotate the strut as necessary until the clevis bracket is positioned straight outward away from the compressor. Install the clamp on the lower end of the coil spring and strut, so the strut is held in place. 5. Install the jounce bumper on the strut shaft. The jounce bumper is to be installed with the smaller end pointing downward toward the lower seat. 6. Install the dust shield on the strut shaft. The bottom of the dust shield will snap past the retainer on top of the strut housing. 7. If disassembled, reinstall the upper spring isolator on the upper spring seat and bearing. 8. Install the upper spring seat and bearing on top of the coil spring. Position the notch formed into the edge of the upper seat straight out away from the compressor. 9. Install the strut upper mount over the strut shaft and onto the top of the upper spring seat and bearing. 10. Loosely install the retaining nut on the strut shaft. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 75 Nm (55 ft. lbs.). 11. Slowly release the tension from the coil spring by backing off the compressor drive completely. As the tension is relieved, make sure the upper mount and seat and bearing align properly. Verify the upper mount does not bind. 12. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 13. Install the strut assembly on the vehicle. INSTALLATION - STRUT ASSEMBLY (FRONT) 1. Install the strut assembly into the strut tower, aligning the three studs on the strut upper mount with the holes in strut tower. Install the three mounting nuts on the studs. Tighten the three nuts to a torque of 34 Nm (300 inch lbs.). 2. Close the hood of the vehicle. CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. 3. Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes. Install the two attaching bolts. The bolts should be installed with so that the nuts face towards the front of the vehicle once installed. Install the nuts. Holding the bolts in place tighten the nuts to a torque of 53 Nm (40 ft. lbs.) plus an additional 90° turn after the specified torque is met. 4. If the vehicle is equipped with Antilock brakes (ABS), attach the ABS wheel speed sensor to the rear of the strut (rearward ear) using its mounting screw. Tighten the mounting screw to a torque of 13 Nm (120 inch lbs.). 5. Attach the ground strap to the rear of the strut (forward ear) using its mounting screw. Tighten the mounting screw to a torque of 13 Nm (120 inch lbs.). 6. Install the tire and wheel assembly. Install and tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5784 7. Lower the vehicle. ADJUSTMENT - ACR STRUT Vehicles equipped with the optional ACR performance package have adjustable struts. A single adjustment knob is located on the bottom of each front and rear strut. The one knob adjusts both bump and rebound characteristics. It adjusts the strut up to 24 different positions (notches or detents), six per revolution. Turn the knob clockwise to increase firmness and counterclockwise to decrease firmness. There is an internal stop at the "full firm" and "full soft" position. New struts (and new vehicles equipped with them) come from the factory set at the "full soft" position. STRUT ADJUSTMENT KNOB (ACR) REMOVAL 1. Raise vehicle. 2. Using a trim stick, carefully pry the knob off the bottom of the strut. INSTALLATION NOTE: There is no specific installed orientation for the adjustment knob. It can be installed in up to 6 different positions as long as the tabs on the knob are lined up with the flats on the internal nut. 1. Install knob center hex onto strut center hex screw, then line up tabs on knob with flats on strut internal nut and push the knob upward, snapping it into place. 2. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5785 3. Adjust the strut if necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5786 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL - STRUT ASSEMBLY (REAR) NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Remove the rear wheel and tire assembly from the vehicle. 3. If the vehicle is equipped with rear drum brakes, remove the screw securing the brake hose bracket to the rear of the strut assembly. 4. If the vehicle is equipped with the antilock brake system (ABS), remove the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly. 5. If equipped with a rear stabilizer bar, remove the nut from the end of the rear stabilizer bar link bolt. Pull the bolt out through the top of the link and remove the link. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5787 6. If the vehicle is equipped with rear disc brakes, perform the following: - Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle. - Remove the disc brake caliper from the knuckle and brake rotor. - Hang the caliper out of the way using a wire hanger or cord. Do not support the caliper by letting it hang by the hydraulic hose. CAUTION: The strut-to-knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckle while removing the nuts, then tap the bolts out using a pin punch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5788 7. Remove the two nuts and bolts attaching the strut to the rear knuckle. 8. Lower the vehicle just enough to access the luggage compartment without letting the tires touch the floor. Access to rear upper strut mount attaching bolts is through the luggage compartment. 9. Open the deck lid. 10. If equipped, remove the carpet from the top of the strut tower. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5789 11. Loosen, but do not completely remove the 3 nuts securing the strut assembly to the strut tower. Grasp the strut assembly to keep it from moving, then remove the 3 mounting nuts at the strut tower. 12. Remove the strut assembly from the knuckle by sliding it away from the knuckle, lowering it between the two lateral arms, then tipping the top outward and removing it out through the well opening. 13. For disassembly procedures of the strut assembly, Refer to STRUT - DISASSEMBLY. DISASSEMBLY - STRUT ASSEMBLY (REAR) The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Service Equipment (PSE) tool W-720O, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. 1. If both struts are being serviced at the same time, mark the coil spring and strut assembly according to which side of the vehicle the strut was removed from, and which strut the coil spring was removed from. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5790 2. Position the strut assembly in the strut coil spring compressor following the manufacturers instructions. Set the lower, then upper hooks on the coil spring. Position the strut clevis bracket straight inward toward the compressor. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed. WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 3. Compress the coil spring until all coil spring tension is removed from the upper mount. 4. Once the spring is sufficiently compressed, install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5791 5. Remove the upper mount from the strut shaft. 6. Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring. 7. Remove the dust shield, then the jounce bumper from the strut shaft by pulling each straight up. 8. Remove the lower spring isolator from the lower spring seat located on the strut. NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with step 10. NOTE: Before removing the coil spring from the compressor, make not of its position in the compressor, for easy reassembly. 9. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 10. Inspect the strut assembly components for the following and replace as necessary: - Inspect the strut for any condition of shaft binding over the full stroke of the shaft. - Inspect the jounce bumper for cracks and signs of deterioration. - Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. - Inspect the dust shield for rips and deterioration. - Inspect the upper and lower spring isolators for material deterioration and distortion. - Inspect the coil spring for any sign of damage to the coating. ASSEMBLY - STRUT ASSEMBLY (REAR) The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Service Equipment (PSE) tool W-720O, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 3. 1. Place the coil spring in the compressor following the manufacturers instructions. Before compressing the spring, rotate the spring to the position determined in the note prior to step 9 in disassembly. 2. Slowly compress the coil spring until enough room is available for strut assembly reassembly. 3. Install the lower spring isolator on the lower spring seat of the strut matching the step built into the isolator with the step in the lower spring seat on the strut. 4. Install the jounce bumper on the strut shaft. The jounce bumper is to be installed with the pointed end pointing downward toward the lower seat. 5. Install the dust shield on the strut shaft. The bottom of the dust shield will snap past the retainer on top of the strut housing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5792 6. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. Rotate the strut until the end of the coil spring fits against the step in the lower spring seat. If done correctly, the clevis on the bottom of the strut should face toward the compressor. 7. Install the clamp on the lower end of the coil spring and strut, so the strut is held in place with the coil spring. NOTE: Before installing the upper mount, check to make sure the correct side mount is being installed. Left and right upper mounts are different. A left mount will be marked with the letter "L" while a right mount will be marked with the letter "R". 8. Install the upper mount over the strut shaft and onto the top of the upper spring. Near the center on the top of the mount is the word "OUT" and an arrow. Point the arrow on the mount in the same direction that the clevis bracket on the lower end of the strut is pointed in. This direction should be straight toward the compressor. 9. Loosely install the retaining nut on the strut shaft. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 75 Nm (55 ft. lbs.). 10. Slowly release the tension from the coil spring by backing off the compressor drive completely. As the tension is relieved, make sure the upper mount's seat aligns properly with the coil spring. 11. Verify the arrow on the upper mount is pointing in the same direction as the strut clevis bracket as mentioned in step 9. 12. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 13. Install the strut assembly on the vehicle. INSTALLATION - STRUT ASSEMBLY (REAR) NOTE: Before proceeding with this procedure, Refer to Service Precautions . 1. To place the strut assembly into mounting position, start the lower end of the strut over the top of the knuckle and down the back between the two lateral arms. Next, lift the top of the strut assembly up into the strut tower aligning the studs on top of the upper mount with the three mounting holes in the strut tower. While holding the strut assembly in place, install the three mounting nuts on the upper mount studs inside the luggage compartment. Tighten the 3 mounting nuts to a torque of 34 Nm (300 inch lbs.). 2. Install the carpeting back on top of the rear strut tower. 3. Close the deck lid. 4. Raise the vehicle. CAUTION: The strut-to-knuckle attaching bolts are serrated and must not be turned during installation. Once installed, hold the bolts stationary in the steering knuckle while installing and tightening the nuts. 5. Align the holes in the strut clevis bracket on the lower end of the strut with the mounting holes in the knuckle. Install the two bolts attaching the strut to the rear knuckle. Install the nuts. Tighten the two nuts to 88 Nm (65 ft. lbs.). 6. If the vehicle is equipped with disc brakes, install the brake rotor and disc brake caliper on the knuckle. Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 7. If equipped with a rear stabilizer bar, reinstall the stabilizer bar link: a. Place the link center sleeve and bushings between the eye in the end of the stabilizer bar and the link mounting bracket on the strut. b. Start the stabilizer bar link bolt with bushing from the top, down through the stabilizer bar, inner link bushings and sleeve, and strut link mounting bracket. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5793 c. Install a lower bushing, then the nut. Do not tighten the nut at this time. 8. If the vehicle is equipped with the antilock brake system (ABS), install the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly. Tighten the mounting screw to a torque of 13 Nm (120 inch lbs.). 9. If the vehicle is equipped with rear drum brakes, install the screw securing the brake hose bracket to the rear of the strut assembly. Tighten the screw to a torque of 31 Nm (275 inch lbs.). 10. Install the tire and wheel assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Repeat the tightening sequence, this time, to full specified torque of 135 Nm (100 ft. lbs.). 11. Lower the vehicle to ground level. 12. Tighten the stabilizer bar link nut to a torque of 23 Nm (200 inch lbs.). 13. Set the rear toe on the vehicle to the required specification if necessary. ADJUSTMENTS ADJUSTMENT - ACR STRUT Vehicles equipped with the optional ACR performance package have adjustable struts. A single adjustment knob is located on the bottom of each front and rear strut. The one knob adjusts both bump and rebound characteristics. It adjusts the strut up to 24 different positions (notches or detents), six per revolution. Turn the knob clockwise to increase firmness and counterclockwise to decrease firmness. There is an internal stop at the "full firm" and "full soft" position. New struts (and new vehicles equipped with them) come from the factory set at the "full soft" position. STRUT ADJUSTMENT KNOB (ACE) REMOVAL 1. Raise vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5794 2. Using a trim stick, carefully pry the knob off the bottom of the strut. INSTALLATION NOTE: There is no specific installed orientation for the adjustment knob. It can be installed in up to 6 different positions as long as the tabs on the knob are lined up with the flats on the internal nut. 1. Install knob center hex onto strut center hex screw, then line up tabs on knob with flats on strut internal nut and push the knob upward, snapping it into place. 2. Lower vehicle. 3. Adjust the strut if necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Bearing Retainer Plate Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Rear To Knuckle Retaining Nut .................................................................................................................... ............................................ 217 Nm (160 ft. lbs.) Wheel Mounting Nuts .......................................................................................................................................................... 109-150 Nm (80-110 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Driveshaft Hub Nut .............................................................................................................................. ............................................ 244 Nm (180 ft. lbs.) Wheel Mounting Nuts ............................................ ........................................................................................................................... 135 Nm (100 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information Vehicle Lifting: Technician Safety Information STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 5807 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 5808 Vehicle Lifting: Vehicle Damage Warnings STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 5809 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation Tires: Description and Operation DESCRIPTION - TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Fig. 1 Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires will have a speed rating letter after the aspect ratio number. For example, the letter "S" indicates that the tire is speed rated up to 112 mph (180 km/h). The speed rating is not always printed on the tire sidewall. Q -up to 100 mph (160 km/h) - S -up to 112 mph (180 km/h) - T -up to 118 mph (190 km/h) - U -up to 124 mph (200 km/h) - H -up to 130 mph (210 km/h) - V -up to 149 mph (240 km/h) - Z -more than 149 mph (240 km/h) (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the sidewall. TIRE CHAINS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Page 5813 Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. DESCRIPTION - RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 km/h (50 mph) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Antilock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. DESCRIPTION - REPLACEMENT TIRES WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. DESCRIPTION - SPARE TIRE (TEMPORARY) The compact temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators Tires: Testing and Inspection Tread Wear Indicators DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 inch), the tread wear indicators will appear as a 13 mm (1/2 inch) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 5816 Tires: Testing and Inspection Tread Wear Patterns DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Fig. 2 Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 5817 Tires: Testing and Inspection Vehicle Lead Diagnosis and Correction DIAGNOSIS AND TESTING - VEHICLE LEAD DIAGNOSIS AND CORRECTION Use the following chart to diagnose a vehicle that has a complaint of a drift or lead condition. The use of this chart will help to determine if the lead condition is the result of a bad tire or is caused by the wheel alignment. VEHICLE LEAD DIAGNOSIS AND CORRECTION PROCEDURE *NOTE: VERIFY THAT LEAD IS NOT RELATED TO STEERING WHEEL NOT CENTERED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning CLEANING - TIRES Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil based solvent or a wire brush for cleaning. Tire Inflation Pressures STANDARD PROCEDURE - TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle (usually on the rear face of the driver's door). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Fig. 4 Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 5820 Fig. 5 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks. Tire Pressure For High Speed Operation STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION Daimler Chrysler Corporation advocates driving at safe speeds within posted speed limits. Speed capacity of a tire is a function of the tire speed rating, inflation pressure and vehicle axle weight. Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. Vehicles loaded to maximum capacity should not be driven at continuous speeds over 120 km/h (75 mph). Never exceed the maximum speed capacity of the tire. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 5821 Tires: Removal and Replacement STANDARD PROCEDURE - TIRE LEAK REPAIRING Fig. 7 For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area. The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the 5 wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 5826 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5827 Wheels: Specifications WHEEL SPECIFICATIONS Wheel Mounting (Lug) Nut Hex Size ................................................................................................... .................................................................. 19 mm Wheel Mounting Stud Size ................................... ...................................................................................................................................... M12 x 1.5 mm Wheel Mounting (Lug) Nut Torque .................................................................................................................................................. 135 Nm (100 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5828 Wheels: Description and Operation DESCRIPTION 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 lock-on wheel covers use large nose wheel nuts. The wheel nuts are externally threaded so that the wheel covers can be attached to the wheel nuts. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5829 Wheels: Testing and Inspection DIAGNOSIS AND TESTING - WHEEL INSPECTION Inspect wheels for: Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The 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. WARNING: REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5830 Wheels: Service and Repair CLEANING WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar Wheel Treatment or Mopar Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Bearing Retainer Plate Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Rear To Knuckle Retaining Nut .................................................................................................................... ............................................ 217 Nm (160 ft. lbs.) Wheel Mounting Nuts .......................................................................................................................................................... 109-150 Nm (80-110 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair REMOVAL 1. Raise the vehicle. CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. 2. Unthread and remove the 5 nuts attaching the wheel and wheel cover to the vehicle. 3. Remove the wheel cover using care not to let the tire and wheel assembly fall off the vehicle. INSTALLATION CAUTION: Installing the wheel mounting nuts without having good metal-to-mental contact between the back of the wheel and the hub mounted brake disc or drum could cause the wheel to bind and eventually cause loosening of the wheel mounting nuts. CAUTION: Never use oil or grease on wheel studs or wheel mounting nuts. 1. With the tire and wheel assembly positioned on the wheel studs without the wheel mounting nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover on the hub mounted studs. 2. Install and lightly tighten the wheel mounting nuts in the proper sequence. 3. Lower the vehicle. 4. Progressively tighten the 5 wheel mounting nuts in the proper sequence until tightened to half of the specified torque. Finally, tighten the wheel mounting nuts in the proper sequence to 135 Nm (100 ft. lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Driveshaft Hub Nut .............................................................................................................................. ............................................ 244 Nm (180 ft. lbs.) Wheel Mounting Nuts ............................................ ........................................................................................................................... 135 Nm (100 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut Hex Size ................................................................................................................................................... 135 Nm (100 ft. lbs.) For Tightening Sequence refer to Wheels and Tires, Service and Repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front WHEEL MOUNTING STUDS - FRONT REMOVAL Use the following procedure to remove and install one of five studs on one wheel hub. 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle. 4. Remove the disc brake caliper from the steering knuckle. The caliper is removed by first tipping either the top (right side) or bottom (left side) of the caliper away from the brake rotor, then pulling the caliper off the opposite end's caliper slide abutment (on the knuckle) and rotor. 5. Hang the caliper out of the way using a wire hanger or cord. Do not support the caliper by letting it hang by the hydraulic hose. 6. Remove any retainer clips from the wheel mounting studs. Remove the brake rotor from the front hub. CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 7. Install a wheel mounting nut on the wheel mounting stud being removed from the hub far enough so the threads on the stud are even with end of lug nut. Rotate the hub so the stud requiring removal is aligned with notch cast into front of the steering knuckle. Install Remover, Special Tool C-4150A, on hub flange and wheel stud . 8. Tighten the remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 5846 remover from the hub. Remove the nut from the stud, then remove the stud from the flange. INSTALLATION Use the following procedure to remove and install one of five studs on one wheel hub. Fig. 62 1. Install the wheel mounting stud in the flange of hub from the rear side. Install several washers and a wheel mounting nut on the stud. The wheel mounting nut must be installed with the flat side of the wheel mounting nut against the washers to eliminate binding. 2. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the flange of the hub. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers from the stud. 3. Install the brake rotor on the hub. 4. Install the disc brake caliper (with pads) on the brake rotor and steering knuckle. The left side caliper is installed by first sliding the top of the caliper past the top abutment on the steering knuckle to hook the top edge of the caliper, then pushing the lower end of the caliper into place against the knuckle. The right side caliper is installed by first sliding the bottom edge of the caliper past the lower abutment on the steering knuckle to hook the lower edge of the caliper, then pushing the top of the caliper into place against the steering knuckle. 5. Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle . Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the tire and wheel assembly. Install the wheel mounting nuts and tighten them to a torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 5847 Wheel Fastener: Service and Repair Rear WHEEL MOUNTING STUDS - REAR REMOVAL CAUTION: DO NOT hammer studs 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. 1. Remove the hub and bearing from the vehicle. CAUTION: Take care to keep hub and bearing assembly from falling during stud removal. Damage to the hub and bearing could result. 2. Position the hub and bearing assembly under a hydraulic press ram, supported by a 21 mm deep well impact socket under the stud to be replaced. 3. Press the stud out of the hub flange and into the socket well. 4. Remove the hub and bearing assembly from the press. 5. Remove the stud from the socket. INSTALLATION CAUTION: DO NOT hammer studs into the hub flange. If a stud is installed in such a manner, damage to the hub and bearing assembly may occur leading to premature bearing failure. 1. Install wheel stud into stud hole in hub and bearing assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 5848 2. Position the hub and bearing assembly face down with stud pointing down into the well of the 21 mm socket. The hydraulic press ram must line up with the stud. 3. Press the stud into the hub flange until it bottoms. 4. Remove the hub and bearing assembly from the press. 5. Install the hub and bearing on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations Accumulator HVAC: Locations Fig.12 Accumulator - Typical The accumulator is mounted in the engine compartment between the evaporator outlet and the compressor suction port. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 5853 Accumulator HVAC: Description and Operation Fig.49 Accumulator - Typical The accumulator is mounted in the engine compartment between the evaporator outlet and the compressor suction port. An integral mounting bracket is used to secure the accumulator to the right side rail with a screw. Two connectors of the suction and liquid line assembly are sealed to an integral connector block on the top of the accumulator canister with rubber O-ring seals and secured there with two screws. A threaded fitting on the top of the accumulator canister provides the port through which the low pressure clutch cycling switch monitors the refrigerant system pressures. The accumulator cannot be repaired and, if faulty or damaged, it must be replaced. The suction and liquid line assembly, the rubber O-rings and the low pressure clutch cycling switch are available for service replacement. Refrigerant enters the accumulator canister as a low pressure vapor through the inlet tube. Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag located inside the accumulator canister absorbs any moisture which may have entered and become trapped within the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 5854 Accumulator HVAC: Service and Repair REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the battery negative cable. 3. If the vehicle is so equipped, relocate the vehicle speed control servo as necessary to access the accumulator. 4. Remove the low pressure clutch cycling switch from the accumulator. Fig.50 Accumulator Remove/Install 5. Remove the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 6. Disconnect the two refrigerant line fittings of the suction and liquid line assembly from the accumulator connector block inlet and outlet ports. 7. Remove the rubber O-ring seal from the refrigerant line fittings of the suction and liquid line assembly and discard. 8. Install plugs in, or tape over the opened accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 9. Remove the screw that secures the accumulator mounting bracket to the right side rail. 10. Remove the accumulator from the engine compartment. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Position the accumulator into the engine compartment. 2. Install and tighten the screw that secures the accumulator mounting bracket to the right side rail. Tighten the screw to 11.3 Nm (100 in. lbs.). 3. Remove the tape or plugs from the accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings of the suction and liquid line assembly. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Reconnect the refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 6. Install and tighten the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. Tighten the screws to 2.3 Nm (20 in. lbs.). 7. Reinstall the low pressure clutch cycling switch onto the accumulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Locations > Page 5855 8. If the vehicle is so equipped, reinstall the vehicle speed control servo. 9. Reconnect the battery negative cable. 10. Evacuate the refrigerant system. NOTE: If the accumulator is replaced, add 89 milli-liters (3 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 11. Charge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Diagrams A/C Cycling Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig.25 A/C Vacuum Line RECIRCULATION DOOR ACTUATOR - LHD The vehicle uses vacuum to operate only the recirculation door All other controls are cable When vacuum is supplied to the actuator, the door moves to the Recirculation position The actuator is spring loaded so the door moves to the Outside-air position when there is no vacuum supplied The operation of the door can be viewed by removing the blower motor and looking up into the unit inlet Normally, vacuum is supplied to the actuator by placing the Circulation control knob in the Recirculation position The Mode and the circulation control are mechanically interlocked so the circulation control cannot be placed in the RECIRC position if the mode control is at or between the mix and defrost positions Vacuum is supplied to the actuator only when circulation control is at the RECIRC position If the circulation control is between the outside air position and RECIRC position the system will be in outside air If the circulation control is in the RECIRC position and the mode control is moved from the floor to the defrost positions, the circulation control will move from the RECIRC position, to the outside air position beginning at the mix position This is to prevent window fogging. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Page 5863 Air Door Actuator / Motor: Service and Repair REMOVAL The recirculation door actuator is a vacuum controlled actuator used to control movement of the recirculation door in air conditioner equipped vehicles. The instrument panel must be removed from the vehicle to gain access to the recirculation door actuator. 1. Remove the battery negative cable. 2. Remove instrument panel from vehicle. 3. Disconnect vacuum line harness connector from the nipple on the recirculation door actuator. 4. Release the latch that secures the recirculation door actuator mount to the stanchion on the Heater-A/C unit housing, and disengage the recirculation door actuator from the housing. Fig.26 Recirculation Door Actuator And Linkage 5. Disconnect the recirculation door actuator linkage from the recirculation door lever. 6. Remove the recirculation door actuator from the Heater-A/C unit housing. INSTALLATION The recirculation door actuator is a vacuum controlled actuator used to control movement of the recirculation door in air conditioned equipped vehicles. 1. Position the recirculation door actuator to the Heater-A/C unit housing. 2. Reconnect the recirculation door actuator linkage to the recirculation door lever. 3. Align the recirculation door actuator mount to the stanchion on the Heater-A/C unit housing, and press it onto the stanchion firmly and to engage the latch. 4. Reconnect the vacuum harness connector to the nipple on the recirculation door actuator. 5. Reinstall the Instrument Panel. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Temperature Control Cable Adjustment Air Door Cable: Adjustments Temperature Control Cable Adjustment 1. Engage cable to actuator arm on temperature door and attach to housing. 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 gray 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Temperature Control Cable Adjustment > Page 5868 Air Door Cable: Adjustments Mode Control Cable Adjustment 1. Engage cable to actuator arm lever on mode door and attach to housing. 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 gray 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable Replacement Air Door Cable: Service and Repair Mode Door Cable Replacement NOTE:The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.22 Instrument Panel Center Bezel & Knobs 2. Remove instrument panel center stack bezel. Fig.23 HVAC Center Air Duct & Control Head 3. Remove center air duct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable Replacement > Page 5871 Fig.24 HVAC Control Head Cables 4. Remove heater-A/C control head and disconnect cable. 5. Disconnect the mode control cable end from the mode door lever. 6. Remove the mode control cable through the instrument panel heater-A/C control opening. INSTALLATION 1. Position the mode control cable through the instrument panel heater-A/C control opening. 2. Reach through the instrument panel center air duct opening to access and reconnect the mode control cable end to the mode door lever. 3. Install and tighten the screw that secures the mode control cable housing. Tighten the screw to 2.3 Nm (20 in. lbs.). 4. Install the instrument panel center stack bezel. 5. Reinstall the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable Replacement > Page 5872 Air Door Cable: Service and Repair Temperature Door Cable Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel center stack bezel. 3. Remove the center air duct from the instrument panel. 4. Remove heater-A/C control. 5. Reach through the instrument panel center air duct opening to access and remove the screw that secures the temperature control cable housing retainer to the top of the heater-A/C unit housing. 6. Disconnect cable at control panel. Remove control from instrument panel. Fig.27 HVAC Housing Cables - (Typical) 7. Disconnect the temperature control cable end from the blend-air door lever. 8. Remove the temperature control cable through the instrument panel heater-A/C control opening. INSTALLATION 1. Position the temperature control cable through the instrument panel heater-A/C control opening.. 2. Reach through the instrument panel center air duct opening to access and reconnect the temperature control cable end to the blend-air door lever. 3. Install and tighten the screw that secures the temperature control cable housing retainer to the top of the heater-A/C unit housing. Tighten the screw to 2.3 Nm (20 in. lbs.). 4. Reinstall the heater-A/C control into the instrument panel. 5. Install the instrument panel center stack bezel. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Procedures Air Duct: Procedures CENTER AIR OUTLET DUCT REMOVAL Fig.29 Dash Board - Front View 1. Remove the center bezel from the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Center Bezel Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Bezel 2. Remove the screws that secure the center air outlet duct to the instrument panel. 3. Disengage the center air outlet duct from the air outlet distribution duct. 4. Remove the center air outlet duct from the instrument panel. INSTALLATION 1. Install the center air outlet duct to the instrument panel. 2. Engage the center air outlet duct to the air outlet distribution duct. 3. Install the screws that secure the center air outlet duct to the instrument panel. Tighten to 2.3 Nm (20 in. lbs.). 4. Install the center bezel to the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Center Bezel Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Bezel Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Procedures > Page 5877 Air Duct: Removal and Replacement AIR EXHAUSTER REMOVAL 1. Hoist rear end of vehicle and support on safety stands. 2. From behind rear bumper fascia below quarter panel, disengage clips attaching body vent to trunk well. Fig. 9 3. Remove body vent from vehicle (Fig. 9). INSTALLATION 1. Place body vent in vehicle. 2. From behind rear bumper fascia below quarter panel, engage clips attaching body vent to trunk well. 3. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Description and Operation Air Register: Description and Operation AIR OUTLETS The demisters direct air from the unit housing through the outlets located on the top corners of the instrument panel. The demisters operate when the mode selector is anywhere between floor and defrost settings. Some air may be noticeable from the demister outlets when the mode selector is in the bi-level to floor positions. AIR FLOW DISTRIBUTION Fig.39 Dash Board - Front View Based upon the system mode selected, conditioned air can exit the standard heater-only or optional heater-A/C unit housing through one or a combination of the three main housing outlets: defrost, panel or floor. The defrost outlet is located on the top of the housing, the panel outlet is located on the face of the housing and the floor outlet is located on the bottom of the housing. Once the conditioned air exits the unit housing, it is further directed through molded plastic ducts to the various outlets in the vehicle interior. These outlets and their locations are as follows: - Defroster Outlet - A single large defroster outlet is located in the center of the instrument panel top cover, near the base of the windshield. - Side Window Demister Outlets - There are two side window demister outlets, one is located at each outboard end of the instrument panel top cover, near the belt line at the A-pillars. - Panel Outlets - There are four panel outlets in the instrument panel, one located near each outboard end of the instrument panel facing the rear of the vehicle and two located near the top of the instrument panel center bezel. - Front Floor Outlets - There are four front floor outlets, two located above each side of the floor panel center tunnel near the dash panel. - Rear Floor Outlets - There are two rear floor outlets, one located on each side of the floor panel center tunnel near the front of each rear seat foot well. The defroster outlet receives airflow from the unit housing through the molded plastic defroster duct, which is snapped onto the unit housing defroster outlet and secured by two tabs to mounting slots in the dash panel. The airflow from the defroster outlet is directed by fixed vanes in the defroster outlet grille and cannot be adjusted. The defroster outlet grille is integral to the instrument panel top cover. The side window demister outlets receive airflow from the unit housing through the air outlet distribution duct, two molded plastic demister hoses and, on the right side only, an intermediate duct. The air outlet distribution duct is secured to the instrument panel with screws and receives airflow through the panel outlet of the unit housing. The airflow from the side window demister outlets is directed by fixed vanes in the demister outlet grilles and cannot be adjusted. The side window demister outlet grilles are integral to the instrument panel top cover. The panel outlets also receive airflow from the unit housing through the air outlet distribution duct. Molded plastic panel outlet ducts and, on the left side only, an intermediate elbow direct airflow from the distribution duct to the outboard panel outlets, while a center air outlet duct directs airflow from the distribution duct to the two center panel outlets. The airflow from each of the panel outlets is adjustable. A knob in the center of each panel outlet grille is used in a joystick fashion to adjust a center diffuser that changes the airflow direction, and a knob on the outer edge of each panel outlet grille opens or closes a shutter to turn airflow on or off through that outlet. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Description and Operation > Page 5881 The front and rear floor outlets receive airflow from the unit housing through the floor distribution duct. The front floor outlets are integral to the molded plastic floor distribution duct, which is secured to the bottom of the unit housing. A molded plastic rear seat duct elbow is fitted to the bottom of the floor distribution duct and directs airflow through a molded plastic duct beneath the carpet on the right side of the floor panel center tunnel to the right rear floor outlet. The right floor duct also features a crossover fitting that joins the right floor duct to the left floor duct over the top of the floor panel center tunnel to direct airflow to the left rear floor outlet. None of the floor outlets can be adjusted. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5885 Ambient Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5886 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the compass/temp module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 degrees C (140 degrees F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 degrees C (140 degrees F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 degrees C (-49 degrees F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 degrees C (-49 degrees F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5887 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: 0 degrees C (32 degrees F) Sensor Resistance = 29.33 - 35.99 Kilohms 10 degrees C (50 degrees F) Sensor Resistance = 17.99 - 21.81 Kilohms 20 degrees C (68 degrees F) Sensor Resistance = 11.37 - 13.61 Kilohms 25 degrees C (77 degrees F) Sensor Resistance = 9.12 - 10.86 Kilohms 30 degrees C (86 degrees F) Sensor Resistance = 7.37 - 8.75 Kilohms 40 degrees C (104 degrees F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5888 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable. 2. Working under the front of the vehicle, remove the necessary components to access the ambient temperature sensor. 3. Disconnect the ambient temperature sensor electrical connector. 4. Remove the ambient temperature sensor retaining screw and remove the sensor from the vehicle. INSTALLATION 1. Connect the ambient temperature sensor electrical connector. 2. Position the ambient temperature sensor and install the retaining screw. 3. Install the removed components. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations The blower motor is located on the bottom right side of the unit housing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views A/C-Heater Blower Motor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5894 Blower Motor: Description and Operation The blower motor wheel is only serviced with the blower motor. The wheel and the motor are balanced as an assembly. If the blower motor wheel requires replacement, the blower motor must also be replaced. The blower motor will only operate when the ignition switch is in the On position, and the blower control switch is in any position except Off. The blower motor circuit is protected by a fuse in the instrument panel fuse block. The blower motor speed is controlled by regulating the battery feed through the blower control switch and the blower motor resistor. The blower motor and wheel are used to control the velocity of air moving through the heater-only or heater-A/C unit housing. The blower motor controls the velocity of the air flowing through the heater-A/C housing by spinning the blower wheel within the housing at the selected speed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5895 Blower Motor: Testing and Inspection Fig.30 Blower Motor Electrical Diagnosis For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring, diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The following chart will give you a basic check list on the blower motor circuit. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With Air Conditioning Blower Motor: Service and Repair With Air Conditioning NOTE: The blower motor is located on the bottom right side of the unit housing. The blower motor can be removed from the vehicle without having to remove the unit housing assembly. REMOVAL 1. Remove left side scuff plate. 2. Pull back carpet. 3. Disconnect blower motor wiring connector. Fig.31 Blower Motor Retaining Screws 4. Remove blower motor retaining screws, and lower blower motor assembly from unit housing. INSTALLATION 1. Position the blower motor into the unit housing. 2. Install the blower motor retaining screws. 3. Connect the wire harness to the blower motor. 4. Reposition the right side carpet. 5. Install the left side scuff plate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With Air Conditioning > Page 5898 Blower Motor: Service and Repair Without Air Conditioning NOTE: The blower motor is located on the bottom right side of the unit housing. The blower motor can be removed from the vehicle without having to remove the unit housing assembly. REMOVAL 1. Disconnect blower motor wiring connector. Fig.32 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 1. Position the blower motor in the unit housing. 2. Rotate the blower motor clockwise until tab snaps into the locked position, approximately 1/8 turn. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations Blower Motor Resistor: Component Locations Fig.18 Blower Motor Resistor Block The blower motor resistor is located in the cowl, at the base of the windshield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 5903 Blower Motor Resistor: Connector Locations Fig. 7 Rear Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Component Locations > Page 5904 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5905 Blower Motor Resistor Block Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5906 Blower Motor Resistor: Service Precautions CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5907 Blower Motor Resistor: Description and Operation Fig.19 Blower Motor 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. 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5908 Blower Motor Resistor: Service and Repair CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed. REMOVAL 1. Remove windshield wipers. 2. Remove cowl top screen. Fig.20 Blower Motor Resistors 3. Disconnect the resistor block wiring connector. 4. Remove/unsnap resistor block from vehicle. 5. Remove the resistor block from the vehicle. INSTALLATION Fig.21 Blower Motor Resistor Block 1. Snap the new Blower Motor Resistor Block into place. 2. Connect the resistor block wiring connector. 3. Install the cowl top screen. 4. Install the windshield wipers. 5. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Compressor Clutch Air Gap .................................................................................................................................... 0.35 - 0.65 mm (0.014 - 0.026 in.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5916 A/C Compressor Clutch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5917 Compressor Clutch: Service Precautions 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5918 Compressor Clutch: Service and Repair A/C COMPRESSOR CLUTCH REMOVAL Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Fig.4 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. Fig.5 Clutch Plate And Shim(s) 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). NOTE: Use care not to lose any of the 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5919 Fig.6 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers, and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Fig.7 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 the back of the field coil with hole in compressor end housing, position the field coil into place. Make sure that lead wires are properly Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5920 routed, and fasten the coil wire bracket/ground retaining screw. NOTE: A new snap ring must be used. The bevel side of the snap ring must be outward. 2. Install field coil retaining snap ring with Snap Ring Pliers. Press snap ring to make sure it is properly seated in the groove. 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. Do not mar the pulley frictional surface. Fig.8 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. Press the snap ring to make sure it is properly seated in the groove. 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: a. Attach a dial indicator to front plate so that movement of the plate can be measured. b. With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. c. The readings should be 0.35 - 0.65 mm (0.014 - 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 17.5 ± 2 Nm (155 ± 20 in. lbs.) torque. 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 speed at 1500 2000 rpm, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions Compressor Clutch Coil: Service Precautions CAUTION: - Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. - 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions > Page 5924 Compressor Clutch Coil: Service and Repair A/C COMPRESSOR CLUTCH COIL REMOVAL Compressor assembly must be removed from mounting. Refrigerant discharge is not necessary. Fig.13 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. Fig.14 Clutch Plate And Shim(s) 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). NOTE: Use care not to lose any of the 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions > Page 5925 Fig.15 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers, and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Fig.16 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions > Page 5926 INSTALLATION 1. Align pin in the back of the field coil with hole in compressor end housing, position the field coil into place. Make sure that lead wires are properly routed, and fasten the coil wire bracket/ground retaining screw. NOTE: A new snap ring must be used. The bevel side of the snap ring must be outward. 2. Install field coil retaining snap ring with Snap Ring Pliers. Press snap ring to make sure it is properly seated in the groove. 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. Do not mar the pulley frictional surface. Fig.17 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. Press the snap ring to make sure it is properly seated in the groove. 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: a. Attach a dial indicator to front plate so that movement of the plate can be measured. b. With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. c. 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 17.5 ± 2 Nm (155 ± 20 in. lbs.) torque. 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. 9. Install the compressor on the engine. 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5930 A/C Compressor Clutch Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5931 Compressor Clutch Relay: Diagrams Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5932 A/C Compressor Clutch Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5933 Compressor Clutch Relay: Description and Operation Fig.6 A/C Compressor Clutch Relay A/C COMPRESSOR CLUTCH RELAY The A/C compressor clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for A/C compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the A/C compressor clutch relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The factory-installed A/C compressor clutch relay cannot be adjusted or repaired. If the relay is damaged or faulty it must be replaced. The A/C compressor clutch relay is an electromechanical switch that uses a low current input from the Powertrain Control Module (PCM) to control the high current output to the Compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the PDC. The inputs and outputs of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5934 the A/C compressor clutch relay include: The common feed terminal (30) receives a battery current input from a fuse in the PDC through a fused B(+) circuit at all times. - The coil ground terminal (85) receives a ground input from the PCM through the A/C compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from a fuse in the fuse block module through a fused ignition switch output (run-start) circuit only when the ignition switch is in the ON or Start positions. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the A/C compressor clutch relay output circuit only when the A/C compressor clutch relay coil is energized. The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C compressor clutch relay coil is de-energized. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5935 Compressor Clutch Relay: Testing and Inspection Test 1 - 4 Test 5 SYMPTOM CHECKING THE A/C RELAY OUTPUT POSSIBLE CAUSES - A/C clutch relay operation - Ground circuit open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5936 - A/C clutch - Fused B+ circuit - A/C clutch output circuit - A/C clutch relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5937 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for A/C compressor clutch relay identification and location. 4. Remove the A/C compressor clutch relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper A/C compressor clutch relay location. 2. Position the A/C compressor clutch relay in the proper receptacle in the PDC. 3. Align the A/C compressor clutch relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the A/C compressor clutch relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condenser Lines .......................................................................................................................... ....................................5 Nm (3.7 ft. lbs) (45 In. Lbs) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5941 Condenser HVAC: Locations Fig.3 Condenser The condenser is integral to a cooling module which includes the radiator, the electric cooling fan, the fan shroud, air seals and an automatic transmission oil cooler on models so equipped. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - LHD Condenser HVAC: Description and Operation A/C Condenser - LHD The condenser is integral to a cooling module which includes the radiator, the electric cooling fan, the fan shroud, air seals and an automatic transmission oil cooler on models so equipped. The cooling module is located in the air flow in the front of the engine compartment behind the front grille. The condenser cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The cooling module must be removed from the vehicle in order to access the condenser for service. The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins. When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - LHD > Page 5944 Condenser HVAC: Description and Operation A/C Condenser - RHD Fig.42 A/C Refrigerant Lines - Condenser The condenser is integral to a cooling module which includes the radiator, the electric cooling fan, the fan shroud, air seals and an automatic transmission oil cooler on models so equipped The cooling module is located in the air flow in the front of the engine compartment behind the front grille. The condenser cannot be repaired or adjusted and, if faulty or damaged, it must be replaced The cooling module must be removed from the vehicle in order to access the condenser for service The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins When the refrigerant gas gives up its heat, it condenses When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5945 Condenser HVAC: Service and Repair A/C CONDENSER 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. REMOVAL WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE CONDENSER. 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. 2. Remove battery support strut. Fig.42 Condenser Refrigerant Lines - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5946 Fig.43 Condenser Refrigerant Lines - RHD 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 1. Tilt the radiator back and position the condenser in the vehicle. 2. Install the condenser to radiator mounting screws. 3. Install the upper radiator mounts. 4. Install the refrigerant lines to the condenser. 5. Install the battery support strut. 6. Tighten the condenser refrigerant lines to 5 Nm (45 in. lbs). 7. Evacuate the refrigerant system. 8. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations A/C Heater Control Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views A/C-Heater Control Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5952 Control Assembly: Description and Operation A/C-HEATER CONTROL Both the heater-only and heater-A/C systems use a combination of, electrical, cable, and vacuum controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Refer to the owner's manual in the vehicle glove box for more information on the features, use, and suggested operation of these controls. The heater-only or heater-A/C control panel is located to the right of the instrument cluster on the instrument panel. The control panel contains rotary-type knobs. There is a blower motor speed switch, mode control switch, temperature control, and airflow control. The heater-only or heater-A/C control panel cannot be repaired. If faulty or damaged, the entire unit must be replaced. The control knobs and the illumination lamps are available for service replacement. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5953 Control Assembly: Service and Repair A/C-HEATER CONTROL REMOVAL Fig.10 Instrument Panel Center Bezel & Knobs 1. Remove the instrument panel center stack bezel. Fig.11 HVAC Center Air Duct & Control Head 2. Remove the center air duct. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5954 Fig.12 HVAC Control Head Cables 3. Remove the heater-A/C control head and disconnect the cable. INSTALLATION 1. Connect the control head cable and install the heater-A/C control head to the dash. 2. Install the center air duct. 3. Install the instrument panel center stack bezel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Coolant Temperature Sensor / Switch HVAC > Component Information > Application and ID Coolant Temperature Sensor / Switch HVAC: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Climate Controls .................................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) 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 5966 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 (L4-2.0L VIN F HO (2003)) 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 5967 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 (L4-2.0L VIN F HO (2003)) 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 5968 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 (L4-2.0L VIN F HO (2003)) 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 5969 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 (L4-2.0L VIN F HO (2003)) 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 5970 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 (L4-2.0L VIN F HO (2003)) 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 5971 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 (L4-2.0L VIN F HO (2003)) 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 5972 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 (L4-2.0L VIN F HO (2003)) 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 5973 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 (L4-2.0L VIN F HO (2003)) 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 5974 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 (L4-2.0L VIN F HO (2003)) 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 5975 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 (L4-2.0L VIN F HO (2003)) 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 5976 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 (L4-2.0L VIN F HO (2003)) 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 5977 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5987 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5988 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5989 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5990 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5991 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5992 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5993 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5994 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5995 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5996 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5997 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 09-007-04 > Mar > 04 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5998 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > Page 5999 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the vehicle. Fig.13 Battery Tray Removal 2. Remove two nuts to the rear and two bolts to the front of the battery tray (Fig. 13). 3. Remove the tray retaining bolt under the center of the tray. 4. Slide battery tray out form under the air cleaner assembly Do not remove the air cleaner assembly 5. Remove battery tray from vehicle. INSTALLATION 1. Slide battery tray in under the air cleaner assembly 2. Install two nuts at the rear and two bolts at the front of the battery tray. 3. Install the bolt located under the tray. 4. Install the battery in the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the single battery hold down retaining bolt. 3. Remove the battery hold down from the vehicle. INSTALLATION 1. Install the battery hold down in the vehicle. 2. Install the single battery hold down retaining bolt 3. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Component Information > Service and Repair > Battery Holddown > Page 6003 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the vehicle. Fig.13 Battery Tray Removal 2. Remove two nuts to the rear and two bolts to the front of the battery tray (Fig. 13). 3. Remove the tray retaining bolt under the center of the tray. 4. Slide battery tray out form under the air cleaner assembly Do not remove the air cleaner assembly 5. Remove battery tray from vehicle. INSTALLATION 1. Slide battery tray in under the air cleaner assembly 2. Install two nuts at the rear and two bolts at the front of the battery tray. 3. Install the bolt located under the tray. 4. Install the battery in the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Component Information > Specifications > Capacity Specifications Differential Fluid - M/T: Capacity Specifications Type ................................................................................................................................. Mopar ATF +4 (Automatic Transmission Fluid - Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. NOTE: The 41TE Automatic and T350 Manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Component Information > Specifications > Capacity Specifications > Page 6007 Differential Fluid - M/T: Fluid Type Specifications Type ................................................................................................................................. Mopar ATF +4 (Automatic Transmission Fluid - Type 9602) LUBRICANT/ADDITIVES NV T350 (A-578) transaxles use Mopar ATF +4 (Automatic Transmission Fluid - Type 9602). Hypoid gear lube or engine oil should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used. The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. NOTE: The 41TE Automatic and T350 Manual transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Component Information > Locations Oil Pressure Sensor: Locations Fig. 13 Engine (Left Rear) (2.0L) - LHD Fig. 44 Engine (Left Rear) (2.0L) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Component Information > Locations > Page 6010 Engine Oil Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description and Operation Evaporator Drain Tube: Description and Operation CONDENSATION DRAIN TUBE Condensation that accumulates in the evaporator housing is drained by a tube through the dash and on to the ground. This tube must be kept open to prevent condensate water from collecting in the bottom of the housing. The tapered end of the drain tube is designed to keep contaminants from entering the heater A/C unit housing. If the tube is pinched or blocked, condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle. If the tube is damaged, it should be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair > Condensation Drain Tube - LHD Evaporator Drain Tube: Service and Repair Condensation Drain Tube - LHD REMOVAL 1. Raise vehicle on a suitable lift. Fig.65 Condensate Water Drain Tube - Typical 2. Locate rubber drain tube on right side of dash panel under the hood. 3. Squeeze clamp and remove drain tube. INSTALLATION 1. Squeeze the retaining tube over the nipple. 2. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair > Condensation Drain Tube - LHD > Page 6016 Evaporator Drain Tube: Service and Repair Condensation Drain Tube - RHD REMOVAL 1. Raise vehicle on a suitable lift Fig.65 Condensate Water Drain Tube - Typical 2. Locate rubber drain tube on left side of dash panel under the hood. 3. Squeeze clamp and remove drain tube INSTALLATION 1. Squeeze the retaining clamp and install the tube over the nipple 2. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Fig.22 Evaporator Probe Location - Typical The evaporator probe is located in the A/C housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6020 Evaporator Temperature Sensor / Switch: Description and Operation EVAPORATOR TEMPERATURE SENSOR The evaporator probe can be replaced without having to remove the A/C housing from the vehicle. The evaporator probe is located in the A/C 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 drops below the freeze point. It cycles ON when the evaporator temperature rises above the 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 housing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6021 Evaporator Temperature Sensor / Switch: Testing and Inspection The work area and vehicle must be between 16 °C (60 °F) and 32 °C (90 °F) when testing the switch. Fig.21 Evaporator Probe Harness Connector 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. 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. 7. Close all doors and windows. Place a thermometer in the center discharge vent. 8. If the clutch does not begin to cycle off between 2 - 7 °C (35 - 45 °F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6022 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be removed without removing the A/C Housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Fig.22 Evaporator Probe Location - Typical 2. Remove rubber grommet from evaporator/ blower module. 3. Note which of the three pilot holes the evaporator probe is located in. 4. Pull probe out of evaporator fins. INSTALLATION NOTE: The evaporator probe can be installed without removing the A/C Housing from the vehicle. 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 of approximately 1/8 inch diameter, and make a new hole. Make the hole 1/4 inch above, or below the original hole in the evaporator core. 3. Insert the new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations A Variable Orifice Valve (VOV) is installed in the liquid line between the outlet of the condenser and the inlet of the evaporator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 6026 Expansion Block/Orifice Tube: Description and Operation A/C VARIABLE ORIFICE TUBE A Variable Orifice Valve (VOV) is installed in the liquid line between the outlet of the condenser and the inlet of the evaporator. The inlet end of the Variable Orifice Valve has a nylon mesh filter screen, which filters the refrigerant and helps to reduce the potential for blockage of the metering orifices by refrigerant system contaminants. The outlet end of the tube has a nylon mesh diffuser screen. The O-rings on the plastic body of the VOV seal the tube to the inside of the liquid line and prevent refrigerant from bypassing the metering orifices. The VOV is only serviced as an integral part of the liquid line. The VOV cannot be adjusted or repaired and, if faulty or plugged, the liquid line unit must be replaced. The VOV meters the flow of liquid refrigerant into the evaporator coil. The VOV contains two orifices which work in parallel. The fixed orifice works along with the variable port to regulate refrigerant expansion in the evaporator in a manner that is suitable for most operating conditions. The high-pressure liquid refrigerant from the condenser expands into a low-pressure liquid/vapor as it passes through the metering orifices and diffuser screen of the VOV The VOV varies the flow of refrigerant in response to the temperature of the refrigerant exiting the condenser. A thermostatic bimetal coil wrapped around the valve body is affected by the refrigerant temperature changes, which opens or closes the variable port to regulate refrigerant flow. As the refrigerant temperature increases, the variable port is progressively closed. A higher temperature (while idling) produces more restriction. A lower temperature (at road speed) produces less restriction. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 6027 Expansion Block/Orifice Tube: Service and Repair REMOVAL - INSTALLATION The Variable Orifice Valve (VOV) is located in the liquid line near the condenser. If the VOV is faulty or plugged, the liquid line unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications Expansion Valve: Specifications Expansion Valve bolt ........................................................................................................................... ...................................11 Nm (8.1 ft. lbs) (97 in. lbs) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 6031 Expansion Valve: Service Precautions WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO2. PERSONAL INJURY CAN RESULT. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 6032 Expansion Valve: Description and Operation A/C VARIABLE ORIFICE TUBE A Variable Orifice Valve (VOV) is installed in the liquid line between the outlet of the condenser and the inlet of the evaporator. The inlet end of the Variable Orifice Valve has a nylon mesh filter screen, which filters the refrigerant and helps to reduce the potential for blockage of the metering orifices by refrigerant system contaminants. The outlet end of the tube has a nylon mesh diffuser screen. The O-rings on the plastic body of the VOV seal the tube to the inside of the liquid line and prevent refrigerant from bypassing the metering orifices. The VOV is only serviced as an integral part of the liquid line. The VOV cannot be adjusted or repaired and, if faulty or plugged, the liquid line unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 6033 Expansion Valve: Testing and Inspection NOTE: - Expansion valve tests should be performed after compressor tests. - 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. Review Safety Precautions and Warnings in the General Information. The work area and vehicle must be 21 to 27 °C (70 °C 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. 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 CO). 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 - 241 kPa (15 - 35 psi). If not, replace expansion valve. 9. When expansion valve test is complete, test A/C overall performance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 6034 Expansion Valve: Service and Repair REMOVAL & INSTALLATION The Variable Orifice Valve (VOV) is located in the liquid line near the condenser. If the VOV is faulty or plugged, the liquid line unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heater Core: Locations Fig.14 Heater Core The heater core is located in the heater-A/C unit housing, under the instrument panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 6038 Heater Core: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DO NOT OPEN THE RADIATOR DRAIN-COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 6039 Heater Core: Description and Operation Fig.51 Heater Core HEATER CORE The heater core is located in the heater-A/C unit housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. One end of the core is fitted with a molded plastic tank that includes the integral heater core hose nipples. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Cooling System for more information on the engine cooling system, the engine coolant and the heater hoses. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 6040 Heater Core: Service and Repair HEATER CORE WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: DO NOT OPEN THE RADIATOR DRAIN-COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. REMOVAL 1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to: "Engine, Cooling, and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Evacuate the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 4. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 5. Remove the refrigerant lines from the evaporator connections. 6. Remove the heater core coolant supply hoses from the heater core. INSTALLATION Refer to HVAC Housing Assembly for heater core installation procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service Precautions Heater Hose: Service Precautions 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. - When installing hoses to heater core inlet or outlet nipples DO NOT exert excessive pressure. The heater core may become damaged and leak engine coolant. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement - LHD HEATER INLET HOSE - LHD 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. Fig.54 Heater Hose Assembly - LHD 2.0L (Typical 2.4L) 2. Using spring tension clamp pliers (or equivalent), to remove clamps at end of heater hose to be removed. 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Heater Inlet Hose Replacement - RHD HEATER INLET HOSE - RHD 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6046 1. Drain engine cooling system. Fig.46 Heater Hose Assembly - RHD 2.0L 2. Using spring tension clamp pliers (or equivalent), to remove clamps at end of heater hose to be removed 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6047 Heater Hose: Service and Repair Heater Return Hose Replacement Heater Return Hose Replacement - LHD HEATER RETURN HOSE - LHD CAUTION: When removing hoses from the heater core inlet nipples DO NOT exert excessive 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. Fig.54 Heater Hose Assembly - LHD 2.0L (Typical 2.4L) 2. Using spring tension clamp pliers (or equivalent), to remove the clamps at the end of the heater hoses to be removed. 3. Carefully rotate the hose back and forth while pulling away from the connector nipple. INSTALLATION CAUTION: When installing hoses to heater core inlet or outlet nipples DO NOT exert excessive pressure. The heater core may become damaged and leak engine coolant. 1. Carefully rotate the hose back and forth while pushing the hose onto the connector nipple. 2. Using spring tension pliers, install the clamps at the end of the heater hose being installed. 3. Refill the cooling system. Heater Return Hose Replacement - RHD HEATER RETURN HOSE - RHD CAUTION: When removing hoses from the heater core inlet nipples DO NOT exert excessive pressure. The heater core may become damaged and Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6048 leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. Fig.46 Heater Hose Assembly - RHD 2.0L 2. Using spring tension clamp pliers (or equivalent), to remove the clamps at the end of the heater hoses to be removed. 3. Carefully rotate the hose back and forth while pulling away from the connector nipple. INSTALLATION 1. Carefully rotate the hose back and forth while pushing the hose onto the connector nipple. 2. Using spring tension pliers, install the clamps at the end of the heater hose being installed. 3. Refill the cooling system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Technician Safety Information High Pressure Safety Valve HVAC: Technician Safety Information 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. MIXTURE 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Technician Safety Information > Page 6053 High Pressure Safety Valve HVAC: Vehicle Damage Warnings 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. MIXTURE 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Page 6054 High Pressure Safety Valve HVAC: Service and Repair HIGH PRESSURE RELIEF VALVE 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. MIXTURE 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. 2. Rotate the high pressure relief valve counterclockwise and separate relief valve from the compressor INSTALLATION 1. Install a new O-ring. Lubricate the O-ring with refrigerant oil. NOTE: Use only refrigerant oil specified for use in this A/C system. 2. Position and rotate the compressor high pressure relief valve clockwise to install. 3. Evacuate the refrigerant system . 4. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Line Retainer Bolt ..................................................................................................................................................... 23 Nm (16.9 ft. lbs) (203 in. lbs.) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Technician Safety Information Hose/Line HVAC: Technician Safety Information WARNING: - THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THE OPERATION. - REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Technician Safety Information > Page 6060 Hose/Line HVAC: Vehicle Damage Warnings CAUTION: - The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. - 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line Hose/Line HVAC: Description and Operation A/C Discharge Hose/Line A/C Discharge Line - LHD Fig.43 A/C Compressor Lines The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. A/C Discharge Line - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 6063 Fig.44 A/C Compressor Lines The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 6064 Hose/Line HVAC: Description and Operation A/C Liquid Hose/Line Liquid Line - LHD The liquid line is the line that goes from the condenser to the receiver-drier. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. Liquid Line - RHD The liquid line is the line that goes from the condenser to the receiver-drier. It has no serviceable parts except the rubber O-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 6065 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line Suction Line - LHD 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 O-rings on all other connections. There are no serviceable parts on the suction line other than the rubber O-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. The refrigerant lines used for this vehicle are common between the two optional engines in order to reduce complexity. The following refrigerant lines are available for service replacement on this vehicle: Fig.60 A/C Compressor Lines - LHD - Discharge line - The discharge line is a flexible hose type line that is connected from the discharge port of the compressor to the inlet (upper fitting) of the condenser. It has no serviceable parts except the rubber O-ring seals used on the fittings at each end of the line. If the discharge line is damaged or faulty, it must be replaced. - Liquid line - The liquid line is a flexible hose type line that is connected between the outlet (lower fitting) of the condenser and the mid-line connector block of the suction and liquid line assembly. The liquid line also contains the variable orifice valve. It has no serviceable parts except the rubber O-ring seals used on the fittings at each end of the line. If the liquid line or the variable orifice valve are damaged or faulty, the liquid line unit must be replaced. - Suction line - The suction line is a flexible hose type line that is connected between the mid-line connector block of the suction and liquid line assembly and the suction port of the compressor. It has no serviceable parts except the rubber O-ring seals used on the fittings at each end of the line. If the suction line is damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 6066 Fig.61 A/C Service Ports - (Typical) - Suction and liquid line assembly - The suction and liquid line assembly is a formed tubing type line assembly that includes the mid-line connector block, a connector block for the evaporator, inlet and outlet line fittings for the accumulator and both A/C service ports. The A/C service port caps, the A/C service port valve cores, the gasket used to seal the connector block at the evaporator and the rubber O-ring seals for the line fittings at the accumulator are all available for service replacement. If any other part of the suction and liquid line assembly is damaged or faulty, the assembly must be replaced. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant line connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Suction Line - RHD 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 O-rings on all other connections. There are no serviceable parts on the suction line other than the rubber O-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. The refrigerant lines used for this vehicle are common between the two optional engines in order to reduce complexity. The following refrigerant lines are available for service replacement on this vehicle: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 6067 Fig.52 A/C Refrigerant Lines - Compressor - Discharge line - The discharge line is a flexible hose type line that is connected from the discharge port of the compressor to the inlet (upper fitting) of the condenser. It has no serviceable parts except the rubber 0-ring seals used on the fittings at each end of the line. If the discharge line is damaged or faulty, it must be replaced. - Liquid line - The liquid line is a flexible hose type line that is connected between the outlet (lower fitting) of the condenser and the mid-line connector block of the suction and liquid line assembly. The liquid line also contains the variable orifice valve. It has no serviceable parts except the rubber 0-ring seals used on the fittings at each end of the line. If the liquid line or the variable orifice valve are damaged or faulty, the liquid line unit must be replaced. - Suction line - The suction line is a flexible hose type line that is connected between the mid-line connector block of the suction and liquid line assembly and the suction port of the compressor. It has no serviceable parts except the rubber 0-ring seals used on the fittings at each end of the line. If the suction line is damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 6068 Fig.53 A/C Service Ports - LHD Shown (Typical RHD) - Suction and liquid line assembly - The suction and liquid line assembly is a formed tubing type line assembly that includes the mid-line connector block, a connector block for the evaporator, inlet and outlet line fittings for the accumulator and both A/C service ports. The A/C service port caps, the A/C service port valve cores, the gasket used to seal the connector block at the evaporator and the rubber 0-ring seals for the line fittings at the accumulator are all available for service replacement. If any other part of the suction and liquid line assembly is damaged or faulty, the assembly must be replaced. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant line connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement A/C Discharge Line Replacement - LHD REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system Fig.44 Discharge Line 2. From the top side of the vehicle, remove line at compressor. 3. From the bottom side of the vehicle, remove line at condenser. INSTALLATION WARNING: THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Position the A/C discharge line in the vehicle and install the condenser end. Tighten the connections to 12 Nm (108 in. lbs.) 2. Lower the vehicle and install the compressor end of the discharge line. Tighten the connections to 12 Nm ( 108 in. lbs.) 3. Evacuate the refrigerant system. 4. Recharge the A/C system. A/C Discharge Line Replacement - RHD WARNING: THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6071 Fig.45 High Pressure Cut Out Switch Location 2. From the top side of the vehicle, remove line at compressor. 3. From the bottom side of the vehicle, remove line at condenser. INSTALLATION 1. Position the A/C discharge line in the vehicle and install the condenser end. Tighten the connections to 12 Nm (108 in. lbs.) 2. Lower the vehicle and install the compressor end of the discharge line. Tighten the connections to 12 Nm ( 108 in. lbs.) 3. Evacuate the refrigerant system. 4. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6072 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Liquid Line Replacement - LHD WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system 2. Disconnect liquid line at drier. 3. Disconnect liquid line at condenser. 4. Remove the liquid line. INSTALLATION NOTE: Replacement of ale line seals is required anytime connections are opened. Failure to replace seals could result in a refrigerant leak. 1. Connect the liquid line at the drier. 2. Connect the liquid line at the condenser. 3. Evacuate the A/C system. 4. Recharge the refrigerant system. Liquid Line Replacement - RHD WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. 2. Disconnect liquid line at drier. 3. Disconnect liquid line at condenser. 4. Remove the liquid line. INSTALLATION NOTE: Replacement of a/c line seals is required anytime connections are opened. Failure to replace seals could result in a refrigerant leak. 1. Connect the liquid line at the drier. 2. Connect the liquid line at the condenser. 3. Evacuate the A/C system. 4. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6073 Hose/Line HVAC: Service and Repair A/C Suction and Liquid Hose/Line Replacement Suction and Liquid Line Replacement - LHD WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the battery negative cable. 3. If the vehicle is so equipped, relocate the vehicle speed control servo as necessary to access the accumulator. Refer to Vehicle Speed Control System for the proper procedures. Fig.64 A/C Accumulator And Low Pressure Switch 4. Remove the nut that secures the liquid line fitting (outboard fitting) to the mid-line connector block of the suction and liquid line assembly. 5. Disconnect the liquid line fitting from the mid-line connector block of the suction and liquid line assembly. 6. Remove the rubber O-ring seal from the refrigerant line fitting of the liquid line and discard. 7. Install plugs in, or tape over the opened mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 8. Remove the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. 9. Disconnect the suction line fitting from the mid-line connector block of the suction and liquid line assembly. 10. Remove the rubber O-ring seal from the refrigerant line fitting of the suction line and discard. 11. Install plugs in, or tape over the opened mid-line connector block suction line port and the refrigerant line fitting of the suction line. 12. Remove the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 13. Disconnect the two refrigerant line fittings of the suction and liquid line assembly from the accumulator connector block inlet and outlet ports. 14. Remove the rubber O-ring seal from the refrigerant line fittings of the suction and liquid line assembly and discard. 15. Install plugs in, or tape over the opened accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 16. Remove the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. 17. Disconnect the suction and liquid line assembly evaporator connector block from the evaporator. 18. Remove the gasket from the suction and liquid line assembly evaporator connector block and discard. 19. Install plugs in, or tape over the opened suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 20. Remove the suction and liquid line assembly from the engine compartment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6074 INSTALLATION 1. Position the suction and liquid line assembly into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 3. Align the suction and liquid line assembly evaporator connector block and a new gasket to the evaporator inlet and outlet ports. 4. Install and tighten the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. Tighten the upper screw to 11.3 Nm (100 in. lbs.) first, then tighten the lower screw. 5. Remove the tape or plugs from the accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings of the suction and liquid line assembly. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 7. Reconnect the refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 8. Install and tighten the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. Tighten the screws to 2.3 Nm (20 in. lbs.). 9. Remove the tape or plugs from the mid-line connector block suction line port and the refrigerant line fitting of the suction line. 10. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the suction line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 11. Reconnect the suction line fitting to the mid-line connector block suction line port of the suction and liquid line assembly. 12. Install and tighten the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the nut to 4.5 Nm (40 in. lbs.). 13. Remove the tape or plugs from the mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the liquid line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 15. Reconnect the liquid line fitting to the mid-line connector block liquid line port of the suction and liquid line assembly. 16. Install and tighten the nut that secures the liquid line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the nut to 4.5 Nm (40 in. lbs.). 17. If the vehicle is so equipped, reinstall the vehicle speed control servo. Refer to Vehicle Speed Control System for the proper procedures. 18. Reconnect the battery negative cable. 19. Evacuate the refrigerant system. Refer to Refrigerant System Evacuate in this group for the proper procedures. 20. Charge the refrigerant system. Refer to Refrigerant System Charge in this group for the proper procedures. Suction and Liquid Line Replacement - RHD WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the battery negative cable. 3. If the vehicle is so equipped, relocate the vehicle speed control servo as necessary to access the accumulator. Refer to Vehicle Speed Control System for the proper procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6075 Fig.56 A/C Refrigerant Lines - Accumulator/Evaporator - LHD (Typical - RHD) 4. Remove the nut that secures the liquid line fitting (outboard fitting) to the mid-line connector block of the suction and liquid line assembly. 5. Disconnect the liquid line fitting from the mid-line connector block of the suction and liquid line assembly. 6. Remove the rubber O-ring seal from the refrigerant line fitting of the liquid line and discard. 7. Install plugs in, or tape over the opened mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 8. Remove the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. 9. Disconnect the suction line fitting from the mid-line connector block of the suction and liquid line assembly. 10. Remove the rubber O-ring seal from the refrigerant line fitting of the suction line and discard. 11. Install plugs in, or tape over the opened mid-line connector block suction line port and the refrigerant line fitting of the suction line. 12. Remove the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the accumulator connector block inlet and outlet ports. 13. Disconnect the two refrigerant line fittings of the suction and liquid line assembly from the accumulator connector block inlet and outlet ports. 14. Remove the rubber O-ring seal from the refrigerant line fittings of the suction and liquid line assembly and discard. 15. Install plugs in, or tape over the opened accumulator connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 16. Remove the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. 17. Disconnect the suction and liquid line assembly evaporator connector block from the evaporator. 18. Remove the gasket from the suction and liquid line assembly evaporator connector block and discard. 19. Install plugs in, or tape over the opened suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 20. Remove the suction and liquid line assembly from the engine compartment. INSTALLATION 1. Position the suction and liquid line assembly into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports. 3. Align the suction and liquid line assembly evaporator connector block and a new gasket to the evaporator inlet and outlet ports. 4. Install and tighten the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator. Tighten the upper screw to 11.3 Nm (100 in. lbs.) first, then tighten the lower screw. 5. Remove the tape or plugs from the receiver-drier connector block inlet and outlet ports and the refrigerant line fittings of the suction and liquid line assembly. 6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings of the suction and liquid line assembly. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 7. Reconnect the refrigerant line fittings of the suction and liquid line assembly to the receiver-drier connector block inlet and outlet ports. 8. Install and tighten the two screws that secure the two refrigerant line fittings of the suction and liquid line assembly to the receiver-drier connector block inlet and outlet ports. Tighten the screws to 2.3 Nm (20 in. lbs.). 9. Remove the tape or plugs from the mid-line connector block suction line port and the refrigerant line fitting of the suction line. 10. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the suction line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 11. Reconnect the suction line fitting to the mid-line connector block suction line port of the suction and liquid line assembly. 12. Install and tighten the nut that secures the suction line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6076 nut to 4.5 Nm (40 in. lbs.). 13. Remove the tape or plugs from the mid-line connector block liquid line port and the refrigerant line fitting of the liquid line. 14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the liquid line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 15. Reconnect the liquid line fitting to the mid-line connector block liquid line port of the suction and liquid line assembly. 16. Install and tighten the nut that secures the liquid line fitting to the mid-line connector block of the suction and liquid line assembly. Tighten the nut to 4.5 Nm (40 in. lbs.). 17. If the vehicle is so equipped, reinstall the vehicle speed control servo. Refer to Vehicle Speed Control System for the proper procedures. 18. Reconnect the battery negative cable. 19. Evacuate the refrigerant system. 20. Charge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6077 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction Line Replacement - LHD REMOVAL WARNING: THE REFRIGERANT MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS. 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. Fig.62 A/C Compressor Lines - LHD 2. Remove line at the accumulator. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6078 Fig.63 A/C Compressor Lines - LHD 3. Remove line at the compressor. INSTALLATION WARNING: THE REFRIGERANT MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS. 1. Install the suction line at the compressor. 2. Install the suction line at the expansion valve. 3. Position the expansion valve and install the retaining bolt. 4. Evacuate the A/C system. 5. Recharge the refrigerant system. Suction Line Replacement - RHD WARNING: THE REFRIGERANT MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6079 Fig.54 Expansion Valve 2. Remove retaining bolt at expansion valve. 3. Remove line at the expansion valve. Fig.55 Accumulator And Lines - LHD (Typical - RHD) 4. Remove line at the compressor. INSTALLATION 1. Install the suction line at the compressor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6080 2. Install the suction line at the expansion valve. 3. Position the expansion valve and install the retaining bolt. 4. Evacuate the A/C system. 5. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement LHD HVAC HOUSING - LHD REMOVAL The instrument panel must be removed in order to remove the heater-A/C Housing. WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Using a refrigerant recovery machine, remove the refrigerant from the A/C system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 2. Remove instrument panel from vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Drain cooling system. Refer to: "Engine, Cooling, and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Remove heater hoses at the dash panel. Place plugs in the heater core outlets to prevent coolant spillage during unit housing removal. 5. Unfasten coolant recovery container and set aside. 6. Remove suction line at expansion valve. Cap open refrigerant lines to prevent moisture and/or dirt from entering. 7. Remove expansion valve from evaporator, and cap fittings. 8. Remove rubber drain tube extension from condensation drain tube. Fig.33 A/C Vacuum Line 9. Disconnect the vacuum harness at the power brake booster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6085 Fig.34 HVAC Housing Defroster Duct - (RHD Shown) 10. Unsnap and remove the defroster duct. Fig.35 Dash Panel Retaining Studs 11. Remove three retaining nuts located in the engine compartment, on the dash panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6086 Fig.36 Housing Screws - LHD 12. Remove the right side retaining screw. 13. Remove remaining nut located on dash panel stud. 14. Disconnect the wiring connectors. 15. Remove assembly from the vehicle. INSTALLATION WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Position the housing in the vehicle. 2. Connect the wire harness connectors. 3. Install the nut on the dash panel stud. 4. Install the three retaining nuts on the engine compartment studs. 5. Snap the defrost duct in place. 6. Connect the vacuum harness at the brake booster. 7. Connect the rubber drain tube to the extension. 8. Install the expansion valve to the evaporator. 9. Remove the protective caps and connect the suction line to the expansion valve. 10. Position and install the coolant recovery container. 11. Install the instrument panel Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 12. Refill the cooling system. Refer to: "Engine, Cooling, and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 13. Evacuate the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 14. Recharge the refrigerant system. RHD REMOVAL NOTE: The instrument panel must be removed in order to remove the heater-A/C Housing. WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Using a refrigerant recovery machine, remove the refrigerant from the A/C system. Refer to: "Heating and Air Conditioning : Service and Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6087 Repair" See: Service and Repair 2. Remove instrument panel from vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Drain cooling system. Refer to: "Engine, Cooling, and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Remove heater hoses at the dash panel. Place plugs in the heater core outlets to prevent coolant spillage during unit housing removal. 5. Unfasten coolant recovery container and set aside. 6. Remove suction line at expansion valve. Cap open refrigerant lines to prevent moisture and/or dirt from entering. 7. Remove expansion valve from evaporator, and cap fittings. 8. Remove rubber drain tube extension from condensation drain tube. Fig.33 A/C Vacuum Line - LHD (Shown) Typical - RHD 9. Disconnect the vacuum harness at the power brake booster. Fig.34 HVAC Housing Defroster Duct - (LHD Shown) Typical - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6088 10. Unsnap and remove the defroster duct. Fig.35 Dash Panel Retaining Studs 11. Remove three retaining nuts located in the engine compartment, on the dash panel. Fig.36 Housing Screws 12. Remove the right side retaining screw. 13. Remove remaining nut located on dash panel stud. 14. Disconnect the wiring connectors. 15. Remove assembly from the vehicle. INSTALLATION WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. 1. Position the housing in the vehicle. 2. Connect the wire harness connectors. 3. Install the nut on the dash panel stud. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6089 4. Install the three retaining nuts on the engine compartment studs. 5. Snap the defrost duct in place. 6. Connect the vacuum harness at the brake booster. 7. Connect the rubber drain tube to the extension. 8. Install the expansion valve to the evaporator. 9. Remove the protective caps and connect the suction line to the expansion valve. 10. Position and install the coolant recovery container. 11. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 12. Refill the cooling system. Refer to: "Engine, Cooling, and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 13. Evacuate the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 14. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6090 Housing Assembly HVAC: Overhaul LHD DISASSEMBLY Use this procedure if any or all of the following items require service: - Heater core - Evaporator - HVAC housing The HVAC housing must be removed from the vehicle before beginning with this procedure Fig.37 HVAC Housing Air Distribution Foam Seals - LHD 1. Separate the air distribution outlet foam seals at the case parting line. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6091 Fig.38 Common Blend-Air HVAC System 2. Remove the evaporator lines foam seal, and heater core tubes foam seal from the unit. 3. Remove the retaining clips and screws that hold the upper and lower housings together. 4. Separate the two halves of the housing. 5. Lift the heater core and evaporator out of the case. ASSEMBLY 1. Install the heater and evaporator cores into the case. 2. Place the two halves of the heater-a/c housing together. 3. Install the retaining clips and screws that hold the upper and lower case housings together. 4. Install the evaporator lines form seals and heater core tube seals to the case housing. 5. Install the air distribution outlet foam seals at the case parting line. RHD DISASSEMBLY NOTE: Use this procedure if any or all of the following items require service: - Heater core - Evaporator - HVAC housing The HVAC housing must be removed from the vehicle before beginning with this procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6092 Fig.37 HVAC Housing Air Distribution Form Seal - LHD Shown (Typical - RHD) 1. Separate the air distribution outlet foam seals at the case parting line. Fig.38 Common Blend-Air HVAC System - LHD Shown (Typical - RHD) 2. Remove the evaporator lines foam seal, and heater core tubes foam seal from the unit. 3. Remove the retaining clips and screws that hold the upper and lower housings together. 4. Separate the two halves of the housing. 5. Lift the heater core and evaporator out of the case. ASSEMBLY Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6093 1. Install the heater and evaporator cores into the case. 2. Place the two halves of the heater-a/c housing together. 3. Install the retaining clips and screws that hold the upper and lower case housings together. 4. Install the evaporator lines form seals and heater core tube seals to the case housing. 5. Install the air distribution outlet foam seals at the case parting line. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations Receiver Dryer: Locations The filter/drier is mounted in a rubber grommet on the left side of the engine compartment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations > Page 6097 Receiver Dryer: Service Precautions WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THE OPERATION . Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations > Page 6098 Receiver Dryer: Service and Repair REMOVAL The filter/drier is mounted in a rubber grommet on the left 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. 1. Evacuate and recover the refrigerant. Fig.30 Heater Hose Assembly - RHD 2.0L 2. Disconnect liquid line from filter/drier. 3. Disconnect liquid line on suction line assembly from filter/drier. 4. Pull filter/drier out of rubber grommet. 5. Remove the filter/drier. INSTALLATION 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. NOTE: Replace all A/C line seals from disassembled components. Failure to replace seals could result in a refrigerant leak. 1. Install the filter/drier in the rubber grommet. 2. Connect the liquid line to the filter/drier. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations > Page 6099 3. Connect the liquid line on the suction line assembly to the filter/drier. 4. Evacuate the refrigerant system. 5. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refer to the refrigerant A/C Specification tag for system capacity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6104 Refrigerant: Fluid Type Specifications A/C Refrigerant Type A/C Refrigerant Type R-134a Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6105 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6106 http://www.macsw.org/ Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6107 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > R-134A Refrigerant Refrigerant: Service and Repair R-134A Refrigerant STANDARD PROCEDURE - R-134A REFRIGERANT This vehicle uses a refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge and/or poor performance. Never add any other type of refrigerant to a system designed to use R-134a refrigerant. System failure will occur. The high pressure service port is located on the filter/drier. The low pressure service port is located on the suction line near the strut tower. Fig. 31 Refrigerant Recovery/Recycling Station - Typical When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > R-134A Refrigerant > Page 6110 Fig. 32 Manifold Gauge Set - Typical A manifold gauge set might be required with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the oil that is specified on the under hood label and/or the compressor housing The use of R 134a will have a positive environmental impact due to its zero ozone depletion and low global warming impact. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > R-134A Refrigerant > Page 6111 Refrigerant: Service and Repair Refrigerant - Recovery STANDARD PROCEDURE - REFRIGERANT RECOVERY WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. See the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service Precautions Refrigerant Filter: Service Precautions WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THE OPERATION. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service Precautions > Page 6115 Refrigerant Filter: Service and Repair REMOVAL The filter/drier is mounted in a rubber grommet on the left 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. 1. Evacuate and recover the refrigerant. Fig.30 Heater Hose Assembly - RHD 2.0L 2. Disconnect liquid line from filter/drier. 3. Disconnect liquid line on suction line assembly from filter/drier. 4. Pull filter/drier out of rubber grommet. 5. Remove the filter/drier. INSTALLATION 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. NOTE: Replace all A/C line seals from disassembled components. Failure to replace seals could result in a refrigerant leak. 1. Install the filter/drier in the rubber grommet. 2. Connect the liquid line to the filter/drier. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service Precautions > Page 6116 3. Connect the liquid line on the suction line assembly to the filter/drier. 4. Evacuate the refrigerant system. 5. Recharge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES Total System ........................................................................................................................................ ......................................................... 180 ml (6.1 oz.) Filter-Drier ............................................................................................................................................ ............................................................ 30 ml (1 oz.) Condenser ........................................................................................................................................... ............................................................... 30 ml (1 oz.) Evaporator ........................................................................................................................................... .............................................................. 59 ml (2 oz.) Refrigerant Lines ................................................................................................................................. ........................................................... 44 ml (1.5 oz.) Compressor ......................................................................................................................................... ..................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6121 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil ..................................................................................................................................... .............................................................. ND-8 PAG PAG - PolyAlkylene Glycol Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6122 Refrigerant Oil: Service Precautions CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6123 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic based PolyAlkylene Glycol (PAG), wax-free lubricant Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The 10S15 and 10S17 compressors used in this vehicle is designed to use an ND-8 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level Refrigerant Oil: Service and Repair Refrigerant Oil Level STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK 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. Refrigerant Oil Capacities When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R-134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level > Page 6126 Refrigerant Oil: Service and Repair Servicing Refrigerant Oil Level STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Recovery/recycling equipment will measure the lubricant being removed. This is the amount of lubricant to be added back to the system. If a new compressor is being installed, drain lubricant from the old compressor, measure the amount drained and discard old lubricant. Drain the lubricant from the new compressor into a clean container. Return the amount of lubricant measured from the old compressor, plus the amount reclaimed from the system back into the new compressor. 1. Discharge refrigerant system using recovery/recycling equipment if charge is present. 2. Disconnect refrigerant lines from A/C compressor. Cap the open lines to prevent moisture from entering system. 3. Remove compressor from vehicle. 4. From suction port on top of compressor, drain lubricant from compressor. 5. Add system capacity minus the capacity of components that have not been replaced. Add lubricant through the suction port on compressor. This is not to exceed 180 ml (6.10 oz.) in total. 6. Install compressor and connect refrigerant lines. Then evacuate and charge refrigerant system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6131 Fig. 2 Engine Compartment (Left) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6132 Fig. 4 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6133 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6134 Fig. 28 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6135 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6136 A/C High Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6137 High Pressure Sensor / Switch: Description and Operation Fig.18 High Pressure Cut Out Switch Location A/C HIGH PRESSURE SWITCH The high pressure cut out switch is located on the rear of the compressor. It turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). The high pressure cut out switch is a factory calibrated unit. The switch cannot be adjusted or repaired and if faulty or damaged, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6138 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 1. Recover refrigerant from A/C system. 2. Disconnect and isolate the battery negative cable. 3. Raise and support the vehicle. High Pressure Cut Out Switch 4. Disconnect the engine wire harness connector from the high pressure cut out switch on the compressor back cover. 5. Using snap ring pliers, remove the internal snap ring that secures the high pressure cut out switch to the switch port in the compressor back cover. 6. Pull the high pressure cut out switch out of the compressor back cover. 7. Install a plug in or tape over the opened switch port on the compressor back cover. 8. Remove the rubber O-ring seal from the high pressure cut out switch and discard. INSTALLATION 1. Clean any foreign matter from the switch mounting bore 2. Install the high pressure cutout switch with a new O-ring. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 3. Remove the tape or plug from the switch port on the compressor back cover. 4. Insert the high pressure cut out switch into the switch port on the compressor back cover. 5. Reconnect the engine wire harness connector to the high pressure cut out switch on the compressor back cover. 6. Lower the vehicle. 7. Reconnect the battery negative cable. 8. Evacuate the refrigerant system. 9. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6142 Fig. 4 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6143 Fig. 27 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6144 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch (LHD) A/C Low Pressure Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6145 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch is a single pole, single throw, pressure actuated switch that is installed in a threaded port into the suction passage of the accumulator. The switch is located on the top of the accumulator in a fitting that contains a Schrader type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with a O-ring to seal the switch plumbing connection. The A/C low pressure switch is a factory calibrated unit. The switch cannot be adjusted or repaired and if faulty or damaged it must be replaced. The A/C low pressure switch monitors the pressure of the refrigerant leaving the accumulator to the compressor. The switch is connected in series electrically with the heater-A/C control blower and mode switches and the high pressure cut out switch between ground and the Powertrain Control Module (PCM). The switch contact open or close the path the ground, signaling the PCM to turn the compressor clutch on and off. This regulates the refrigerant system pressure and controls evaporator temperature. Controlling the evaporator temperature prevents con-densate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The A/C low pressure switch contacts are open when the suction pressure is approximately 152 kPa (22 psi) or lower. The switch contacts will close when the suction pressure rises to approximately 234 - 262 kPa (34 - 38 psi) or above. Lower temperatures, below approximately -1 °C (30 °F), will also cause the switch contacts to open. This is due to the pressure/ temperature relationship of the refrigerant in the system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6146 Low Pressure Sensor / Switch: Testing and Inspection A/C LOW PRESSURE SWITCH Before performing diagnosis of the A/C low pressure switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Also verify that the refrigerant system had the correct refrigerant charge. 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 A/C low pressure 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 A/C low pressure switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6147 Low Pressure Sensor / Switch: Service and Repair A/C LOW PRESSURE SWITCH REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the low pressure cycling switch. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the connector for the A/C low pressure switch from the top connector on the accumulator. 3. Unscrew the A/C low pressure switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator and discard. INSTALLATION NOTE: Replace the O-ring seal before installing the low pressure clutch cycling switch 1. Lubricate the new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the A/C low pressure cycling switch onto the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Reconnect the wiring harness connector to the A/C low pressure switch. 4. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations 8w-10-2 Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6152 A/C Compressor Clutch Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6153 Compressor Clutch Relay: Diagrams Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6154 A/C Compressor Clutch Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6155 Compressor Clutch Relay: Description and Operation Fig.6 A/C Compressor Clutch Relay A/C COMPRESSOR CLUTCH RELAY The A/C compressor clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for A/C compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the A/C compressor clutch relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The factory-installed A/C compressor clutch relay cannot be adjusted or repaired. If the relay is damaged or faulty it must be replaced. The A/C compressor clutch relay is an electromechanical switch that uses a low current input from the Powertrain Control Module (PCM) to control the high current output to the Compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the PDC. The inputs and outputs of Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6156 the A/C compressor clutch relay include: The common feed terminal (30) receives a battery current input from a fuse in the PDC through a fused B(+) circuit at all times. - The coil ground terminal (85) receives a ground input from the PCM through the A/C compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from a fuse in the fuse block module through a fused ignition switch output (run-start) circuit only when the ignition switch is in the ON or Start positions. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the A/C compressor clutch relay output circuit only when the A/C compressor clutch relay coil is energized. The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C compressor clutch relay coil is de-energized. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6157 Compressor Clutch Relay: Testing and Inspection Test 1 - 4 Test 5 SYMPTOM CHECKING THE A/C RELAY OUTPUT POSSIBLE CAUSES - A/C clutch relay operation - Ground circuit open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6158 - A/C clutch - Fused B+ circuit - A/C clutch output circuit - A/C clutch relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6159 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for A/C compressor clutch relay identification and location. 4. Remove the A/C compressor clutch relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper A/C compressor clutch relay location. 2. Position the A/C compressor clutch relay in the proper receptacle in the PDC. 3. Align the A/C compressor clutch relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the A/C compressor clutch relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Diagrams A/C Cycling Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6167 Ambient Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6168 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the compass/temp module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 degrees C (140 degrees F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 degrees C (140 degrees F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 degrees C (-49 degrees F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 degrees C (-49 degrees F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6169 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: 0 degrees C (32 degrees F) Sensor Resistance = 29.33 - 35.99 Kilohms 10 degrees C (50 degrees F) Sensor Resistance = 17.99 - 21.81 Kilohms 20 degrees C (68 degrees F) Sensor Resistance = 11.37 - 13.61 Kilohms 25 degrees C (77 degrees F) Sensor Resistance = 9.12 - 10.86 Kilohms 30 degrees C (86 degrees F) Sensor Resistance = 7.37 - 8.75 Kilohms 40 degrees C (104 degrees F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6170 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable. 2. Working under the front of the vehicle, remove the necessary components to access the ambient temperature sensor. 3. Disconnect the ambient temperature sensor electrical connector. 4. Remove the ambient temperature sensor retaining screw and remove the sensor from the vehicle. INSTALLATION 1. Connect the ambient temperature sensor electrical connector. 2. Position the ambient temperature sensor and install the retaining screw. 3. Install the removed components. 4. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Coolant Temperature Sensor / Switch HVAC > Component Information > Application and ID Coolant Temperature Sensor / Switch HVAC: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Climate Controls .................................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Fig.22 Evaporator Probe Location - Typical The evaporator probe is located in the A/C housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6177 Evaporator Temperature Sensor / Switch: Description and Operation EVAPORATOR TEMPERATURE SENSOR The evaporator probe can be replaced without having to remove the A/C housing from the vehicle. The evaporator probe is located in the A/C 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 drops below the freeze point. It cycles ON when the evaporator temperature rises above the 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 housing. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6178 Evaporator Temperature Sensor / Switch: Testing and Inspection The work area and vehicle must be between 16 °C (60 °F) and 32 °C (90 °F) when testing the switch. Fig.21 Evaporator Probe Harness Connector 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. 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. 7. Close all doors and windows. Place a thermometer in the center discharge vent. 8. If the clutch does not begin to cycle off between 2 - 7 °C (35 - 45 °F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6179 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be removed without removing the A/C Housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Fig.22 Evaporator Probe Location - Typical 2. Remove rubber grommet from evaporator/ blower module. 3. Note which of the three pilot holes the evaporator probe is located in. 4. Pull probe out of evaporator fins. INSTALLATION NOTE: The evaporator probe can be installed without removing the A/C Housing from the vehicle. 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 of approximately 1/8 inch diameter, and make a new hole. Make the hole 1/4 inch above, or below the original hole in the evaporator core. 3. Insert the new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6184 Fig. 2 Engine Compartment (Left) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6185 Fig. 4 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6186 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6187 Fig. 28 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6188 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6189 A/C High Pressure Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6190 High Pressure Sensor / Switch: Description and Operation Fig.18 High Pressure Cut Out Switch Location A/C HIGH PRESSURE SWITCH The high pressure cut out switch is located on the rear of the compressor. It turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). The high pressure cut out switch is a factory calibrated unit. The switch cannot be adjusted or repaired and if faulty or damaged, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6191 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 1. Recover refrigerant from A/C system. 2. Disconnect and isolate the battery negative cable. 3. Raise and support the vehicle. High Pressure Cut Out Switch 4. Disconnect the engine wire harness connector from the high pressure cut out switch on the compressor back cover. 5. Using snap ring pliers, remove the internal snap ring that secures the high pressure cut out switch to the switch port in the compressor back cover. 6. Pull the high pressure cut out switch out of the compressor back cover. 7. Install a plug in or tape over the opened switch port on the compressor back cover. 8. Remove the rubber O-ring seal from the high pressure cut out switch and discard. INSTALLATION 1. Clean any foreign matter from the switch mounting bore 2. Install the high pressure cutout switch with a new O-ring. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 3. Remove the tape or plug from the switch port on the compressor back cover. 4. Insert the high pressure cut out switch into the switch port on the compressor back cover. 5. Reconnect the engine wire harness connector to the high pressure cut out switch on the compressor back cover. 6. Lower the vehicle. 7. Reconnect the battery negative cable. 8. Evacuate the refrigerant system. 9. Recharge the A/C system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6195 Fig. 4 Engine Compartment (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6196 Fig. 27 Engine Compartment (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6197 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch (LHD) A/C Low Pressure Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6198 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch is a single pole, single throw, pressure actuated switch that is installed in a threaded port into the suction passage of the accumulator. The switch is located on the top of the accumulator in a fitting that contains a Schrader type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with a O-ring to seal the switch plumbing connection. The A/C low pressure switch is a factory calibrated unit. The switch cannot be adjusted or repaired and if faulty or damaged it must be replaced. The A/C low pressure switch monitors the pressure of the refrigerant leaving the accumulator to the compressor. The switch is connected in series electrically with the heater-A/C control blower and mode switches and the high pressure cut out switch between ground and the Powertrain Control Module (PCM). The switch contact open or close the path the ground, signaling the PCM to turn the compressor clutch on and off. This regulates the refrigerant system pressure and controls evaporator temperature. Controlling the evaporator temperature prevents con-densate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The A/C low pressure switch contacts are open when the suction pressure is approximately 152 kPa (22 psi) or lower. The switch contacts will close when the suction pressure rises to approximately 234 - 262 kPa (34 - 38 psi) or above. Lower temperatures, below approximately -1 °C (30 °F), will also cause the switch contacts to open. This is due to the pressure/ temperature relationship of the refrigerant in the system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6199 Low Pressure Sensor / Switch: Testing and Inspection A/C LOW PRESSURE SWITCH Before performing diagnosis of the A/C low pressure switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Also verify that the refrigerant system had the correct refrigerant charge. 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 A/C low pressure 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 A/C low pressure switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 6200 Low Pressure Sensor / Switch: Service and Repair A/C LOW PRESSURE SWITCH REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the low pressure cycling switch. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the connector for the A/C low pressure switch from the top connector on the accumulator. 3. Unscrew the A/C low pressure switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator and discard. INSTALLATION NOTE: Replace the O-ring seal before installing the low pressure clutch cycling switch 1. Lubricate the new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the A/C low pressure cycling switch onto the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Reconnect the wiring harness connector to the A/C low pressure switch. 4. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service Precautions Service Port HVAC: Service Precautions 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service Precautions > Page 6204 Service Port HVAC: Description and Operation Fig.39 A/C Service Port Valves A/C SERVICE PORT VALVE CORES The A/C service port valve cores are serviceable items. The high side valve is located on the filter-drier, and the low side valve is situated on the suction line, near the washer fluid reservoir filler. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service Precautions > Page 6205 Service Port HVAC: Service and Repair SERVICE PORT VALVE CORES REMOVAL 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 and tighten. 3. Evacuate the refrigerant system. 4. Recharge the refrigerant system. 5. Install the valve caps. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Testing and Inspection Vacuum Check Valve HVAC: Testing and Inspection Fig.28 Adjust Vacuum Test Bleed Valve - Typical Heater - A/C Vacuum System Diagnosis Use an adjustable vacuum test set (Special Tool C-3707-B) and a suitable vacuum pump to test the heater-A/C vacuum control system. With a finger placed over the end of the vacuum test hose probe, adjust the bleed valve on the test set gauge to obtain a vacuum of exactly 27 kPa (8 in. Hg.). Release and block the end of the probe several times to verify that the vacuum reading returns to the exact 27 kPa (8 in. Hg.) setting. Otherwise, a false reading will be obtained during testing. One-way Check Valve 1. Disconnect the heater-A/C vacuum supply (Black) tube in the engine compartment. This tube passes through an opening in the dash panel. 2. Remove the one-way vacuum check valve. The valve is located on the (Black) vacuum supply hose at the brake power booster. 3. Connect the test set vacuum supply hose to the heater side of the valve. When connected to this side of the check valve, no vacuum should pass and the test set gauge should return to the 27 kPa (8 in. Hg.) setting. If OK, go to step Step 4. If not OK, replace the faulty valve. 4. Connect the test set vacuum supply hose to the engine vacuum side of the valve. When connected to this side of the check valve, vacuum should flow through the valve without restriction. If not OK, replace the faulty valve. Heater-A/C Controls The operation of the Circulation door can be viewed by removing the blower motor and looking up into the unit inlet. 1. Connect the test set vacuum probe to the heater-A/C vacuum supply (Black) hose in the engine compartment. Position the test set gauge so that it can be viewed from the passenger compartment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Testing and Inspection > Page 6209 2. Start with the Mode control in the Panel position and the Circulation control in the Outside-air position. 3. Move the Circulation control to the Recirculation position (the Circulation door should move into the Recirculation position). After a short pause move the Mode control to the Defrost position (the Circulation door should move to the Outside-air position). The test gauge should return to the calibrated setting of 27 kPa (8 in. Hg.) after each selection is made. If the gauge cannot achieve the calibrated setting, the vacuum circuit or a component has a leak. 4. If the gauge achieves the calibrated setting but the door does not move, there is either a pinched vacuum line or a failed actuator. Locating Vacuum Leaks 1. Connect the test vacuum probe to the vehicles (Black) supply hose. Position the vacuum test gauge so it can be viewed from the passenger compartment. 2. Place the Mode in the Panel position and the Circulation control in the Recirculation position. 3. Remove the center instrument panel bezel. 4. Remove the center vent duct. 5. Remove and block the Supply (Black) vacuum line at the control. The test gauge should return to the calibrated setting of 27 kPa (8 in. Hg). If not, there is a leak in the Supply line. 6. If there is no leak in the Supply line, reconnect it to the Control and remove the Actuator Feed (Red) line from the Control. Block the vacuum connection on the Control from where the line was removed. The test gauge should return to the calibrated setting of 27 kPa (8 in. Hg.). If not, there is a leak in the Control. 7. If there is no leak in the Supply line or the Control, reconnect the Actuator Feed (Red) line to the control. Remove and block the Actuator Feed (Red) line at the Actuator. The actuator vacuum port is accessible behind and above the Glove Box. The test gauge should return to the calibrated setting of 27 kPa (8 in. Hg.). If not there is a leak in the Actuator Feed line. 8. If there is no leak in the Supply line, Control, or the Actuator Feed line, the leak must be in the Actuator itself. Connect the Vacuum hose from the Vacuum Test Gauge directly to the Actuator to verify the leak. Locating Pinched Vacuum Lines The operation of the Circulation door can be viewed by removing the blower motor and looking up into the unit inlet. See Blower Motor Wheel and Assembly removal and installation for service procedures. 1. Connect the test vacuum probe to the vehicles (Black) supply hose. Position the vacuum test gauge so it can be viewed from the passenger compartment. 2. Place the Mode in the Panel position and the Circulation control in the Recirculation position. 3. Remove the center instrument panel bezel. 4. Remove the center vent duct. 5. Remove the Supply (Black) vacuum line at the control. The test gauge should drop indicating free flow through the Supply line. If not, there is a blockage in the Supply line. 6. If there is no blockage in the Supply line, reconnect it to the Control. Remove the Actuator Feed (Red) line from the Control. The test gauge should drop indicating free flow through the Supply line and Control. If not the vacuum switches on the Control are not functioning. 7. If there is no blockage in the Supply line or the Control, reconnect the Actuator Feed (Red) line to the control. Remove the Actuator Feed (Red) line at the Actuator. The Actuator vacuum port is accessible behind and above the Glove Box. The test gauge should drop indicating free flow through the supply line, Control, and the Actuator Feed line. If not, there is a blockage in the Actuator Feed line. 8. If there is no blockage in the Supply line, Control, or the Actuator Feed line, the Actuator must have failed. Connect the Vacuum hose from the Vacuum Test Gauge directly to the Actuator to verify the Actuator has failed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System The OEM does not provide a list of restraint system components that should be inspected and/or replaced following a collision. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 6215 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6220 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 6224 Air Bag: Diagrams Driver Airbag Left Seat Airbag Passenger Airbag Right Seat Airbag Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 6225 Air Bag: Service Precautions WARNING: - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. FIRST (Refer to RESTRAINTS/DIAGNOSIS AND TESTING - AIRBAG SYSTEM). - WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 6226 Air Bag: Description and Operation Fig.11 Driver Airbag Location DRIVER AIRBAG The driver airbag protective trim cover is the most visible part of the driver airbag system. The driver airbag is mounted directly to the steering wheel. Located under the airbag trim cover are the horn switch, the folded airbag cushion, and the airbag cushion supporting components. The resistive membrane-type horn switch is secured within a plastic tray between the driver airbag cover and the backer plate which is heat staked on to the driver airbag cover. The driver airbag cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag trim cover and the horn switch are available for service replacement. The driver airbag includes a stamped metal housing to which the cushion and an inflator unit are attached and sealed. The conventional pyrotechnic-type inflator assembly is mounted to studs on the back of the airbag module housing. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas towards the instrument panel through the porous fabric material used on the steering wheel side of the airbag cushion. The protective trim cover is fitted to the front of the airbag and forms a decorative cover in the center of the steering wheel. The inside of the trim cover has locking blocks molded into it that engage a lip on the airbag metal housing. Two stamped metal retainers then fit over the inflator mounting studs on the back of the airbag housing and are engaged in slots on the inside of the cover, securely locking the trim cover into place. The trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch and tray unit upon airbag deployment. Fig.14 Passenger Airbag Location PASSENGER AIRBAG The passenger airbag is located behind the passenger airbag cover, between the glove box and instrument panel top cover. The passenger airbag includes an aluminum housing within which the cushion and inflator are mounted and sealed. Two stamped metal brackets, Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 6227 one on each end of the housing, enclose the cushion and inflator. The mounting scheme consists of two weld studs and a bracket with two tabs off the bottom of the housing. Following a passenger airbag deployment, the passenger airbag and the passenger airbag cover must be replaced. If inspection reveals that the passenger airbag mounting points on the instrument panel have been cracked or damaged, the instrument panel assembly must also be replaced. The passenger airbag cannot be repaired, and must be replaced if deployed or in any way damaged. The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas through the porous fabric material used on each end panel of the airbag cushion. The passenger airbag is secured with nuts to the instrument panel beneath the instrument panel top pad and above the glove box opening. Fig.17 Seat Airbag - Typical Seat Airbags, SIACM SEAT AIRBAG The left and right seat airbags are located in the outboard edge of the front seat backs. The airbag contains a bag, an inflator (small canister of highly compressed gas), and a mounting bracket. The seat airbag cannot be repaired and must be replaced if deployed or in any way damaged. When supplied with the proper electrical signal, the inflator seals the hole in the airbag cushion so it can discharge the compressed gas directly into the cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Air Bag: Service and Repair Driver Airbag REMOVAL When removing a deployed airbag, rubber gloves, eye protection and 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. Fig.12 Driver Airbag Remove/Install 2. Remove speed control switches or covers from steering wheel armature and disconnect the wires. 3. Remove two bolts attaching Driver Airbag from the sides of steering wheel. 4. Lift airbag and disconnect airbag squib wire connector and horn wire. 5. Remove Driver Airbag from vehicle. NOTE: When replacing a deployed driver airbag, the clock spring must also be replaced. Refer to Electrical, Restraints, Clock Spring, Removal. INSTALLATION 1. Connect the squib wire to the airbag. 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 Nm (90 to 100 in. lbs.) torque. 4. Install covers to the steering wheel armature or connect the wire connectors to the speed control switches and install switches. Tighten fastener to 2 Nm (20 in. lbs.) torque. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6230 Air Bag: Service and Repair Driver Airbag Cover REMOVAL The horn switch is integral to the driver airbag trim cover. If either component is faulty or damaged, the entire driver airbag trim cover and horn switch unit must be replaced. 1. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE. 2. Remove the driver airbag from the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG REMOVAL). 3. Remove the plastic wire retainer that captures the horn switch feed pigtail wire between the upper left inflator stud and the inflator on the back of the driver airbag housing. 4. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver airbag housing. 5. Remove the upper and lower trim cover retainers from the airbag housing studs. 6. Remove the horn switch ground pigtail wire eyelet terminal from the upper right airbag housing stud. 7. Disengage the six trim cover locking blocks from the lip around the outside edge of the driver airbag housing and remove the housing from the cover. INSTALLATION 1. Install the housing into the cover. Engage the six trim cover locking blocks to the lip around the outside edge of the driver airbag housing. 2. Install the horn switch ground pigtail wire eyelet terminal to the upper right airbag housing stud. 3. Install the upper and lower trim cover retainers to the airbag housing studs. 4. Install the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver airbag housing. 5. Install the plastic wire retainer that captures the horn switch feed pigtail wire between the upper left inflator stud and the inflator on the back of the driver airbag housing. 6. Install the driver airbag onto the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG INSTALLATION). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. FIRST (Refer to RESTRAINTS/DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6231 Air Bag: Service and Repair Passenger Airbag REMOVAL Non-deployed Module When removing an airbag for any reason other than DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. 2. Wait one minute for the reserve capacitor to discharge before removing non-deployed module. 3. Remove instrument panel top cover. Refer to Body Instrument Panel, Instrument panel Top Cover, Removal. 4. Remove three screws to glove box door and remove door from instrument panel. Fig.15 Passenger Airbag Remove/Install 5. Remove three passenger airbag cover screws attaching cover to top of instrument panel. 6. Remove two passenger airbag cover screws attaching cover to front lower instrument panel. 7. Remove three airbag attaching nuts from the support structure. 8. Lift the airbag up until the wire connector is visible and disconnect the connector. Deployed Module When removing a deployed airbag, 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. Roll/fold airbag towards instrument panel. 2. Close door over folded airbag and tape door closed. 3. Disconnect and isolate the battery negative cable. 4. Remove instrument panel top cover. Refer to Body, Instrument Panel, Instrument panel Top Cover, Removal. 5. Remove three screws to glove box door and remove door from instrument panel. 6. Remove three passenger airbag cover screws attaching cover to top of instrument panel. 7. Remove two passenger airbag cover screws attaching cover to front lower instrument panel. 8. Remove three airbag attaching nuts from the support structure. 9. Lift the airbag up until the wire connector is visible and disconnect the connector. INSTALLATION When installing a module for any reason other than DEPLOYMENT. 1. Connect the passenger airbag wire connector to the airbag. Lower the airbag into the instrument panel in its mounting position. 2. Install the three airbag attaching nuts to the support structure. Tighten the three airbag retaining nuts to 22 to 34 Nm (200 to 300 in. lbs.) torque. 3. Install the two passenger airbag cover screws attaching cover to the front lower instrument panel. Tighten screws to 2 Nm (20 in. lbs.) torque. 4. Install the three passenger airbag cover screws attaching cover to top of instrument panel. Tighten screws to 2 Nm (20 in. lbs.) torque. 5. Install the door onto the instrument panel and install the three screws to the glove box door. Tighten screws to 2 Nm (20 in. lbs.) torque. 6. Install the instrument panel top cover. Refer to Body Instrument Panel, Instrument panel Top Cover, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6232 Air Bag: Service and Repair Seat Airbag REMOVAL 1. Position the left front seat in the full forward position. 2. Open hood. Fig.18 Battery Negative Cable Remove/Install 3. Disconnect and isolate the battery negative cable. 4. Remove front seat from vehicle. Refer to Body, Seats, Front Seat, Removal. Fig.19 Front Seat Back Panel - Typical 5. Remove plastic back panel from the seat back. a. Grasp seat back panel at upper corners. b. Pull rearward on panel until panel disengages on both sides of the upper portion. c. After both upper corners are disengaged from the seat frame, remove the two lower portion attachment screws. 6. Disengage seat back trim cover J-strap from the upper, lower and airbag side of seat back. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6233 Fig.20 Seat Airbag Electrical Connector 7. Disconnect the seat airbag electrical connector. Slide yellow locking tab down to unlock. Then with two fingers, push two side retaining tabs in and pull connector straight from module. 8. Remove the seat airbag retaining nuts. 9. Grasp the upper airbag side of the seat back trim cover and pull trim cover and cushion over top of seat back frame. This will allow room to remove seat airbag without damaging trim cover or cushion. 10. Working between seat back trim cover/cushion and frame carefully unhook seat airbag studs from nylon sleeve and slide seat airbag out of sleeve. Be careful not to tear nylon sleeve as this will affect function of airbag system. CAUTION: Be certain not to tear the side impact airbag module nylon sleeve during removal. INSTALLATION NOTE: The seat airbag connector must face down (toward seat cushion) after installation. 1. Carefully slide the seat airbag in nylon sleeve until mounting studs line up with holes provided in nylon sleeve. Be careful not to tear nylon sleeve as this will affect function of airbag system. CAUTION: The seat airbag must be inside the nylon sleeve before installing retaining nuts. Failure to do so will adversely affect the function of the side impact airbag system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6234 Fig.21 Installing Seat Airbag 2. Pull seat airbag and nylon sleeve assembly up to line up mounting studs and mistake proofing pin with holes provided in seat back frame mounting bracket. Install the seat airbag retaining nuts. Torque to 10.7 Nm (94.7 in. lbs.). 3. Position the upper seat back trim cover and cushion over seat back frame. 4. Connect the seat airbag electrical connector. After initial connector is installed be certain the yellow locking tab is in the upper locked" position. Check to be certain connector cannot be removed once yellow locking tab is positioned. 5. Position seat back trim cover and install seat back trim cover J-straps on the upper, lower and airbag side of seat back frame. 6. Install the plastic back panel on the seat back. a. Inspect seat back panel attachment clips (on upper portion on panel) for damage or excessive deformation. Replace clips if necessary. b. Inspect seat frame back panel lower attachment bracket (where attachment screws engage into frame) for damage or bending. c. If panel attachment lower bracket is bent, bend seat back panel attachment lower bracket back to its original (flat) shape. If bracket is damaged or bent beyond repair, seat back frame must be replaced. d. Inspect seat frame back panel upper attachment bracket (where attachment clips engage into frame) for damage or bending. e. If frame panel upper attachment bracket is bent, bend seat back panel attachment bracket back to its original (flat) shape. If bracket is damaged or bent beyond repair, seat back frame must be replaced. f. Secure back panel upper attachment clips to back panel. g. Position back panel to seat back frame by placing locating feature posts to corresponding locating holes in attachment brackets. h. Apply moderate force to push back panel until upper clips engage into frame on both sides. i. After both upper corners are engaged to seat frame, insert two lower portion attachment screws. j. Torque screws to 2 Nm (8.9 in. lbs.). 7. Install the front seat back in vehicle. Refer to Body Seats, Front Seat, Installation. CAUTION: Be certain plastic back panel is securely installed on the seat back. Failure to do so will adversely affect the side impact airbag system. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. 8. Close hood. 9. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6239 Air Bag Control Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6240 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6241 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6242 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6243 Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6244 Fig. 56 Body (Right) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6245 Air Bag Control Module: Diagrams Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6246 Air Bag Control Module: Service Precautions WARNING: - THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. - DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6247 Air Bag Control Module: Description and Operation Airbag Control Module AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, safing sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn ON the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp ON for 6-8 seconds. If the lamp turns OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6248 Fig.23 Side Impact Airbag Control Module (SIACM) SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) Vehicles equipped with side impact airbags use two side impact airbag control modules. One is located on each side of the vehicle within the body B-pillar. Each Side Impact Airbag Control Module (SIACM) serves as the impact sensor for its seat mounted airbag. The right side SIACM controls the right seat airbag. The left side SIACM controls the left seat air- bag. Each SIACM contains two accelerometers, both accelerometers must agree in order to deploy the side airbag. In the event of a side impact, the appropriate SIACM will send a electronic signal to its airbag, deploying the airbag. The SIACM communicates with the Airbag Control Module (ACM) via the PCI bus circuit. The SIACM perform self-diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem, the SIACM will set both active and stored Diagnostic Trouble Codes (DTC's). If a DTC is active, the SIACM will request that the airbag warning lamp be turned ON. The results of the system test are transmitted on the PCI bus to the ACM once each second or on a change in lamp state (ON/OFF). If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set, the ACM sends a PCI bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp to be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. The SIACM's are not serviceable and must be replaced even if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6249 Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module Air Bag Control Module: Service and Repair Airbag Control Module REMOVAL Fig.1 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove center console. Refer to Body Interior, Floor Console, Removal. Fig.4 Airbag Control Module (ACM) Remove/Install 3. Remove module mounting nuts and remove module. 4. Disconnect ACM 23-way connector. 5. Remove ACM from vehicle. INSTALLATION 1. Connect ACM connector and ensure that the connector and all locking tabs are engaged. CAUTION: USE SUPPLIED NUTS ONLY. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 9.6 to 14 Nm (85 to 125 in. lbs.) torque. 3. Install center console assembly Refer to Body, Interior, Floor Console Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 6252 TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 6253 Air Bag Control Module: Service and Repair Side Impact Airbag Control Module REMOVAL The removal and installation of the driver side and passenger side modules is identical. The orientation of the modules is the only difference (which way they are tilted). WARNING: THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. 1. Open hood. Fig.18 Battery Negative Cable Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Remove the lower seat trim. Locate the connector for the seat airbag which is under the seat on the outboard side, attached to the seat frame. Disconnect the harness side of the connector. This is to engage the shorting Clips to disable the side impact airbag system. 4. Remove the lower B-pillar trim from the appropriate side of the vehicle. Refer to Body, Interior, B-Pillar Trim, Removal. 5. Remove the seat belt retractor. Refer to Electrical, Restraints, Front Seat Belt Retractor, Removal. WARNING: DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 6254 Fig.23 Side Impact Airbag Control Module (SIACM) 6. Remove the SIACM retaining nuts and ground eyelet. 7. Pull SIACM out of B-pillar. Fig.24 SIACM Connector 8. Disconnect the SIACM electrical connector. 9. Remove the SIACM from the vehicle. INSTALLATION The installation of the driver side and passenger side modules is identical. The orientation of the modules is the only difference (which way they are tilted). WARNING: THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. 1. Connect the SIACM electrical connector. 2. Position the SIACM in the B-pillar and install the retaining nuts. Torque the nuts to 41 Nm (360 in. lbs.). NOTE: Place the ground eyelet over the TOP REAR (towards the rear of the vehicle) weld stud when reattaching the SIACM. This location prevents the eyelet from spinning during tightening. 3. Install the seat belt retractor. Refer to Electrical, Restraints, Front Seat Belt Retractor, Installation. 4. Install the lower B-pillar trim. Refer to Body Interior, B-Pillar Trim, Installation. 5. Connect the harness side of the connector. Install the lower seat trim. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. 6. Close hood. 7. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 6258 Clockspring Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 6259 Clockspring Assembly / Spiral Cable: Service Precautions WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 6260 Clockspring Assembly / Spiral Cable: Description and Operation Fig.9 Clockspring Location CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 6261 Clockspring Assembly / Spiral Cable: Adjustments STANDARD PROCEDURE - CLOCK SPRING CENTERING If the rotating tape within the clock spring is not positioned properly with the steering wheel and the front wheels, the clock spring may fail during use. The following procedure MUST BE USED to center the clock spring if: The clock spring is not known to be properly positioned. - The front wheels were moved. - The steering wheel was moved from the half turn (180 degrees) to the right (clockwise) position. 1. Remove clock spring. Refer to Electrical, Restraints, Clock Spring, Removal. 2. Rotate the clock spring rotor in the CLOCKWISE DIRECTION to the end of travel. Do not apply excessive torque. 3. From the end of travel, rotate the rotor three full turns 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 degrees). Engage clock spring locking mechanism. 4. Install the clock spring. Refer to Electrical, Restraints, Clock Spring, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 6262 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL 1. Place the front road wheels in the straight ahead position then: - Rotate the steering wheel half turn (180 degrees) to the right (clockwise). - Lock column with ignition lock cylinder. 2. Disconnect and isolate the battery negative cable. 3. Wait one minute for the reserve capacitor to discharge before removing non-deployed module. 4. Remove steering wheel. Refer to Steering, Column, Steering Wheel, Removal. 5. Remove upper and lower steering column shrouds to gain access to clockspring wiring. Refer to Steering, Column, Upper Shroud Removal. 6. Remove multi-function switch. Refer to Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 7. Disconnect the 7-way connector between the clock spring and the instrument panel wiring harness at the base of the clock spring. Fig.10 Clock Spring Latch Hooks 8. Remove clock spring by lifting the top latch tab up slightly to guide it over the lock housing. The clock spring cannot be repaired, and must be replaced if faulty. 9. Rotate clock spring rotor a half turn (180 degrees) to the left (counter clockwise). 10. Lock the clock spring 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 degrees) 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 clock spring, remove locking wire and rotate clock spring rotor one half turn (180 degrees) to the right (clockwise). Locate the clock spring on the steering shaft and push down on the rotor until the clock spring is fully seated on the steering column. - When installing a new clock spring, position the front wheels straight a head. Remove grenade pin. Rotate clock spring rotor one half turn (180 degrees) to the right (clockwise). 2. Connect the clock spring 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 the multi-function switch. Refer to Lamps/Lighting - Exterior, Multi-Function Switch, Installation. 4. Install steering column shrouds. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clock spring. Pull the horn, airbag and speed control leads through the larger slot. Ensure leads do not get pinched under the steering wheel. 6. Route speed control wires under and behind the airbag module mounting tabs. 7. Connect the horn lead wire and the airbag lead wire to the airbag module. 8. Install the airbag module and tighten bolts to 12 to 14 Nm (105 to 125 in. lbs.) torque. 9. Connect the speed control wires to the switches and install switches. Tighten screws to 2 Nm (20 in. lbs.) torque. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Application and ID Malfunction Lamp / Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Airbag Indicator ................................................................................................................................... ................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6271 Air Bag Control Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6272 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6273 Fig. 27 Center Console - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6274 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6275 Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 6276 Fig. 56 Body (Right) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6277 Air Bag Control Module: Diagrams Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6278 Air Bag Control Module: Service Precautions WARNING: - THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. - DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6279 Air Bag Control Module: Description and Operation Airbag Control Module AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, safing sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn ON the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp ON for 6-8 seconds. If the lamp turns OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6280 Fig.23 Side Impact Airbag Control Module (SIACM) SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) Vehicles equipped with side impact airbags use two side impact airbag control modules. One is located on each side of the vehicle within the body B-pillar. Each Side Impact Airbag Control Module (SIACM) serves as the impact sensor for its seat mounted airbag. The right side SIACM controls the right seat airbag. The left side SIACM controls the left seat air- bag. Each SIACM contains two accelerometers, both accelerometers must agree in order to deploy the side airbag. In the event of a side impact, the appropriate SIACM will send a electronic signal to its airbag, deploying the airbag. The SIACM communicates with the Airbag Control Module (ACM) via the PCI bus circuit. The SIACM perform self-diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem, the SIACM will set both active and stored Diagnostic Trouble Codes (DTC's). If a DTC is active, the SIACM will request that the airbag warning lamp be turned ON. The results of the system test are transmitted on the PCI bus to the ACM once each second or on a change in lamp state (ON/OFF). If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set, the ACM sends a PCI bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp to be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. The SIACM's are not serviceable and must be replaced even if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6281 Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module Air Bag Control Module: Service and Repair Airbag Control Module REMOVAL Fig.1 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove center console. Refer to Body Interior, Floor Console, Removal. Fig.4 Airbag Control Module (ACM) Remove/Install 3. Remove module mounting nuts and remove module. 4. Disconnect ACM 23-way connector. 5. Remove ACM from vehicle. INSTALLATION 1. Connect ACM connector and ensure that the connector and all locking tabs are engaged. CAUTION: USE SUPPLIED NUTS ONLY. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 9.6 to 14 Nm (85 to 125 in. lbs.) torque. 3. Install center console assembly Refer to Body, Interior, Floor Console Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 6284 TESTING - AIRBAG SYSTEM FIRST. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 6285 Air Bag Control Module: Service and Repair Side Impact Airbag Control Module REMOVAL The removal and installation of the driver side and passenger side modules is identical. The orientation of the modules is the only difference (which way they are tilted). WARNING: THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. 1. Open hood. Fig.18 Battery Negative Cable Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Remove the lower seat trim. Locate the connector for the seat airbag which is under the seat on the outboard side, attached to the seat frame. Disconnect the harness side of the connector. This is to engage the shorting Clips to disable the side impact airbag system. 4. Remove the lower B-pillar trim from the appropriate side of the vehicle. Refer to Body, Interior, B-Pillar Trim, Removal. 5. Remove the seat belt retractor. Refer to Electrical, Restraints, Front Seat Belt Retractor, Removal. WARNING: DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 6286 Fig.23 Side Impact Airbag Control Module (SIACM) 6. Remove the SIACM retaining nuts and ground eyelet. 7. Pull SIACM out of B-pillar. Fig.24 SIACM Connector 8. Disconnect the SIACM electrical connector. 9. Remove the SIACM from the vehicle. INSTALLATION The installation of the driver side and passenger side modules is identical. The orientation of the modules is the only difference (which way they are tilted). WARNING: THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. 1. Connect the SIACM electrical connector. 2. Position the SIACM in the B-pillar and install the retaining nuts. Torque the nuts to 41 Nm (360 in. lbs.). NOTE: Place the ground eyelet over the TOP REAR (towards the rear of the vehicle) weld stud when reattaching the SIACM. This location prevents the eyelet from spinning during tightening. 3. Install the seat belt retractor. Refer to Electrical, Restraints, Front Seat Belt Retractor, Installation. 4. Install the lower B-pillar trim. Refer to Body Interior, B-Pillar Trim, Installation. 5. Connect the harness side of the connector. Install the lower seat trim. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. 6. Close hood. 7. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6291 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation Fig.5 Child Tether Assembly Fig.6 Child Tether Anchor Fig.7 Child Tether Assembly Cap CHILD TETHER The Child Tether Assembly consists of the Child Tether Anchor and the Child Tether Assembly Caps. The Child Tether Anchor is not serviceable. The anchor is located on the rear shelf panel. The Child Tether Assembly Cap is not serviceable. The rear trim panel will have to be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6296 Child Seat Tether Attachment: Service and Repair Fig.8 Child Tether Assembly Cap REMOVAL 1. Open Child Tether Assembly Cap Cover to the full open position. 2. Pull cover upward until cover detaches from cap. INSTALLATION 1. Place Child Tether Assembly Cap Cover into position in the cap. 2. Push downward on Child Tether Assembly Cap Cover till it locks into position (will hear part click into position) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 6301 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 6302 Seat Belt: Service Precautions CAUTION: Front seat belt assemblies must be replaced after a collision. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 6303 Seat Belt: Testing and Inspection FASTEN SEAT BELT To test the fasten seat belts function, turn the ignition switch to the ON position with the driver's seat belt unbuckled and fully retracted. The seat belt warning lamp should light for four to eight seconds and the tone should sound three to five times. If the lamp does not light, check the connection at the seat belt retractor. Replace as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat Seat Belt: Service and Repair Seat Belt and Retractor - Front Seat REMOVAL CAUTION: Front seat belt assemblies must be replaced after a collision. 1. Remove B-pillar trim. Fig.13 Front Seat Belt Retractor 2. Remove bolt attaching seat belt retractor to B-pillar. 3. Disconnect the wire connector to the retractor. 4. Remove seat belt retractor from vehicle. INSTALLATION CAUTION: Front seat belt assemblies must be replaced after a collision. 1. Connect the wire connector to the retractor. 2. Install seat belt retractor into vehicle. 3. Install bolt attaching seat belt retractor to B-pillar. Tighten seat belt anchor bolt to 40 Nm (30 ft. lbs.) torque. 4. Install B-pillar trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6306 Seat Belt: Service and Repair Seat Belt and Retractor - Rear Seat REMOVAL 1. Remove rear seat cushion and back. 2. Remove seat belt bezel from parcel shelf cover. 3. Remove rear seat closure panel silencer pad as necessary to gain access to retractor. 4. Remove bolt attaching seat belt lower anchor to floor. Fig.16 Rear Seat Belt & Retractor 5. Remove bolt attaching retractor to rear seat closure panel. 6. Push seat belt bezel and buckle stab through access hole in parcel shelf. 7. From in trunk compartment, remove rear seat belt retractor from vehicle. INSTALLATION 1. Position rear seat belt retractor in trunk compartment. 2. Push seat belt bezel and buckle stab through access hole in rear shelf trim panel. 3. Install bolt attaching retractor to rear seat closure panel. 40 Nm (30 ft. lbs.) torque. 4. Install bolt attaching seat belt lower anchor to floor. Tighten the seat belt bolt to 40 Nm (30 ft. lbs.) torque. 5. Install rear seat closure panel silencer pad. 6. Install seat belt bezel to the rear shelf trim panel. 7. Install rear seat cushion and back. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions Seat Belt Buckle: Service Precautions CAUTION: Front seat belt assemblies must be replaced after a collision. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat Seat Belt Buckle: Service and Repair Seat Belt Buckle - Front Seat REMOVAL CAUTION: Front seat belt assemblies must be replaced after a collision. 1. Remove bolt attaching seat belt buckle from seat anchor. 2. Remove seat belt buckle from seat. INSTALLATION CAUTION: Front seat belt assemblies must be replaced after a collision. 1. Place seat belt buckle in position on seat anchor 2. Install bolt and grommet attaching seat belt buckle to seat anchor Tighten seat belt anchor bolt to 40 Nm (30 ft. lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 6312 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Rear Seat REMOVAL 1. Remove rear seat cushion 2. Remove rear seat belt buckle bolt 3. Remove rear seat belt buckle from vehicle INSTALLATION 1. Install rear seat belt buckle. Tighten the seat belt nut to 57 Nm (42 ft. lbs.) torque. 2. Install rear seat cushion. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Fig. 28 Body (Left Front) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6316 Fig. 56 Body (Right) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6317 Seat Belt Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions Seat Belt Height Adjuster: Service Precautions CAUTION: - Front seat belt assemblies must be replaced after a collision. - Front seat belt adjuster must be in the lowest position when Installing adjuster knob. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions > Page 6321 Seat Belt Height Adjuster: Service and Repair REMOVAL CAUTION: Front seat belt assemblies must be replaced after a collision. Fig.13 Front Seat Belt Retractor 1. Remove B-pillar trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions > Page 6322 Fig.22 Front Shoulder Belt Adjuster 2. Remove the two bolts attaching shoulder belt adjuster to B-pillar. 3. Remove shoulder belt adjuster from vehicle. INSTALLATION CAUTION: Front seat belt assemblies must be replaced after a collision. - Front seat belt adjuster must be in the lowest position when Installing adjuster knob. 1. Place into position the shoulder belt adjuster. 2. Install bolts attaching shoulder belt adjuster to B-pillar. Tighten all seat belt bolts to 40 Nm (30 ft. lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Seat Belt Indicator ............................................................................................................................... .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions Seat Belt Retractor: Service Precautions CAUTION: Front seat belt assemblies must be replaced after a collision. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front REMOVAL CAUTION: Front seat belt assemblies must be replaced after a collision. 1. Remove B-pillar trim. Fig.13 Front Seat Belt Retractor 2. Remove bolt attaching seat belt retractor to B-pillar. 3. Disconnect the wire connector to the retractor. 4. Remove seat belt retractor from vehicle. INSTALLATION CAUTION: Front seat belt assemblies must be replaced after a collision. 1. Connect the wire connector to the retractor. 2. Install seat belt retractor into vehicle. 3. Install bolt attaching seat belt retractor to B-pillar. Tighten seat belt anchor bolt to 40 Nm (30 ft. lbs.) torque. 4. Install B-pillar trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6331 Seat Belt Retractor: Service and Repair Rear Rear Seat Belt and Retractor REMOVAL 1. Remove rear seat cushion and back. 2. Remove seat belt bezel from parcel shelf cover. 3. Remove rear seat closure panel silencer pad as necessary to gain access to retractor. 4. Remove bolt attaching seat belt lower anchor to floor. Fig.16 Rear Seat Belt & Retractor 5. Remove bolt attaching retractor to rear seat closure panel. 6. Push seat belt bezel and buckle stab through access hole in parcel shelf. 7. From in trunk compartment, remove rear seat belt retractor from vehicle. INSTALLATION 1. Position rear seat belt retractor in trunk compartment. 2. Push seat belt bezel and buckle stab through access hole in rear shelf trim panel. 3. Install bolt attaching retractor to rear seat closure panel. 40 Nm (30 ft. lbs.) torque. 4. Install bolt attaching seat belt lower anchor to floor. Tighten the seat belt bolt to 40 Nm (30 ft. lbs.) torque. 5. Install rear seat closure panel silencer pad. 6. Install seat belt bezel to the rear shelf trim panel. 7. Install rear seat cushion and back. Seat Belt and Retractor - Rear Center Three Point REMOVAL 1. Remove rear seat cushion and back 2. Remove seat belt bezel from parcel shelf cover. 3. Remove two push fasteners to NVH cover over retractor. 4. Remove bolt attaching retractor to floor. 5. Remove bolt attaching seat belt lower anchor to floor. 6. Push seat belt bezel and buckle stab through access hole in parcel shelf. 7. From in trunk compartment, remove rear seat belt retractor from vehicle. INSTALLATION 1. Position rear seat belt retractor in trunk compartment. 2. Push seat belt bezel and buckle stab through access hole in rear shelf trim panel. 3. Install bolt attaching retractor to rear floor. Tighten to 40 Nm (30 ft. lbs.) torque. 4. Install the NVH cover and two push fasteners over the center retractor. 5. Install bolt attaching seat belt lower anchor to floor. Tighten the seat belt bolt to 57 Nm (42 ft. lbs.) torque. 6. Install seat belt bezel to the rear shelf trim panel. 7. Install rear seat cushion and back. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Fig. 28 Body (Left Front) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6336 Fig. 56 Body (Right) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6337 Seat Belt Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions Antenna Cable: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 6344 Antenna Cable: Description and Operation ANTENNA BODY & CABLE The antenna body and cable is secured below the fender panel by the antenna cap nut through a mounting hole in the right front fender. The primary coaxial antenna cable is then routed beneath the fender sheet metal and through a entry hole in the right cowl side panel into the interior of the vehicle. Inside the vehicle, the primary coaxial cable is connected to a secondary instrument panel antenna coaxial cable with an in-line connector that is located behind the right kick panel. The secondary coaxial cable is then routed behind the instrument panel to the back of the radio. The antenna body and cable connects the antenna mast to the radio. The radio antenna is an electromagnetic circuit component used to capture radio frequency signals that are broadcast by local commercial radio stations in both the Amplitude Modulating (AM) and Frequency Modulating (FM) frequency ranges. These electromagnetic radio frequency signals induce small electrical modulations into the antenna as they move past the mast. The antenna body transfers the weak electromagnetic radio waves induced into the rigid antenna mast into the center conductor of the flexible primary antenna coaxial cable. The braided outer shield of the antenna coaxial cable is grounded through both the antenna body and the radio chassis, effectively shielding the radio waves as they are conducted to the radio. The radio then tunes and amplifies the weak radio signals into stronger electrical signals in order to operate the audio system speakers. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 6345 Antenna Cable: Testing and Inspection ANTENNA BODY AND CABLE TESTING The following four tests are used to diagnose the antenna with an ohmmeter: Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground to battery ground test - Test 4 - Body ground to antenna coaxial cable shield test. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig.1 Antenna Tests - Typical The ohmmeter test lead connections for each test are shown in the illustration. NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate an antenna cable problem. First, test the primary antenna cable (integral to the antenna body and cable) from the coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel to the antenna body. Then, test the secondary antenna cable (instrument panel antenna cable) from the coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel to the coaxial cable connector at the radio. TEST 1 Test 1 determines if the antenna mast is insulated from ground. Proceed as follows: 1. Disconnect and isolate the antenna coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel. 2. Touch one ohmmeter test lead to the tip of the antenna mast. Touch the other test lead to the antenna cap nut. Check the ohmmeter reading for continuity. 3. There should be no continuity. If OK, go to Test 2. If not OK, replace the faulty antenna body and cable. TEST 2 Test 2 checks the antenna conductor components for an open circuit. This test should be performed first on the entire antenna circuit, from the antenna mast to the center conductor of the coaxial cable connector at the radio. If an open circuit is detected, each of the three antenna conductor components (antenna mast, antenna body and primary cable unit, instrument panel antenna secondary cable) should be isolated and tested individually to locate the exact component that is the source of the open circuit. To begin this test, proceed as follows: 1. Disconnect the instrument panel (secondary) antenna cable coaxial connector from the back of the radio. 2. Touch one ohmmeter test lead to the tip of the antenna mast. Touch the other test lead to the center conductor pin of the instrument panel antenna cable coaxial connector for the radio. Check the ohmmeter reading for continuity. 3. There should be continuity. The ohmmeter should register only a fraction of an ohm resistance. High or infinite resistance indicates a damaged or open antenna conductor. If OK, go to Test 3. If not OK, isolate and test each of the individual antenna conductor components. Replace only the Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 6346 faulty antenna conductor component. TEST 3 Test 3 checks the condition of the vehicle body ground connection. To begin this test, proceed as follows: 1. This test must be performed with the battery positive cable disconnected from the battery. Disconnect and isolate both battery cables, negative cable first. 2. Reconnect the battery negative cable. 3. Touch one ohmmeter test lead to a good clean ground point on the vehicle fender. Touch the other test lead to the battery negative terminal post. Check the ohmmeter reading for continuity. 4. There should be continuity. The ohmmeter should register less than one ohm resistance. High or infinite resistance indicates a loose, corroded, or damaged connection between the battery negative terminal and the vehicle body. If OK, go to Test 4. If not OK, check the battery negative cable connection to the vehicle body and the radio noise suppression ground strap connections to the engine and the vehicle body for being loose or corroded. Clean or tighten these connections as required. TEST 4 Test 4 checks the condition of between the antenna coaxial cable vehicle body ground as follows: 1. Disconnect and isolate the antenna coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel 2. Touch one ohmmeter test lead to a good clean ground point on the vehicle fender Touch the other test lead to the outer crimp on the antenna coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel Check the ohmmeter reading for continuity 3. There should be continuity The ohmmeter should register less than one ohm resistance High or infinite resistance indicates a loose, corroded, or damaged connection between the antenna body and the vehicle body or between the antenna body and the antenna coaxial cable shield If not OK, clean the antenna body to fender mating surfaces and tighten the antenna cap nut to specifications 4. Check the resistance again with an ohmmeter. If the resistance is still more then one ohm, replace the faulty antenna body and cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service Precautions > Page 6347 Antenna Cable: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove antenna mast by unscrewing mast from antenna body. 3. Locate the antenna lead disconnect in the instrument panel wire harness above the passenger side cowl trim panel. Disconnect the antenna cable from the instrument panel cable lead. Mast And Antenna Assembly Mounting 4. Unfasten push pins from the rear of the plastic inner fender shield and move shield to gain access to the base/cable assembly. 5. Remove cap nut and adapter. Remove base/cable assembly from bottom of the load beam. INSTALLATION 1. From under the fender, push the antenna base and cable assembly through the hole in the fender. Seat grommet in the load beam. 2. From above the fender, place adapter, then the cap nut on the base/cable assembly. Tighten the cap nut to 7 Nm (61 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. Install passenger cowl side trim panel 6. Install antenna mast 7. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Component Information > Description and Operation Alarm Horn: Description and Operation SIREN (EXPORT) Fig.6 Vehicle Theft Security Siren Some vehicles equipped with the premium Vehicle Theft Security System (VTSS) utilize a separate siren. This siren is dedicated to the Vehicle Theft Security System (VTSS) and is controlled by the ARKEM module (Remote Keyless Entry). The siren can reach sound decibels as high as 110 dB. A internal battery-backup power source and auto detect feature are also built into the siren. The internal battery-backup provides sufficient power to sound the alarm even if the vehicle's electrical system is depleted. The auto detect feature has the ability to sound the siren if any of the wires (voltage supply, ground and signal) leading to the siren are cut while the system is armed. In the event the vehicle theft security is triggered, the ARKEM module will sound the siren. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Component Information > Description and Operation > Page 6352 Alarm Horn: Service and Repair SIREN (EXPORT) REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear wheel well splash shield. 3. Remove the air blocker to see siren. 4. Disconnect the siren electrical connector. Fig.7 Siren - Remove/Install 5. Remove the siren retaining screws and remove the siren from the vehicle. INSTALLATION 1. Position siren and install retaining screws. 2. Connect the siren electrical connector. 3. Install air blocker in original position. 4. Install the left rear wheel well splash shield. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Alarm Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6361 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Alarm Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6367 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations Fig.9 Sentry Key Immobilizer Module (SKIM) Location Sentry Key Immobilizer Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 6370 Alarm Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 6371 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6372 Sentry Key Immobilizer Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6373 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE (SKIM) Fig.13 Sentry Key Immobilizer Module Fig.14 Sentry Key Immobilizer Module Location The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the instrument cluster, and the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique "Secret Key" code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The "Secret Key" code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the "Secret Key" code can be restored from the PCM by following the SKIM replacement procedure found in the DRB III scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original "Secret Key" code can not be recovered, new ignition keys will be required. The DRB III scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6374 secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the PCM during initialization. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an "invalid key" message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is "invalid key." Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. The SKIM also sends indicator light status messages to the instrument cluster to tell that module how to operate the light. This may consist of turning the light ON for a three (3) second bulb test when the ignition switch is first turned to the ON position. It is also the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement Alarm Module: Service and Repair Sentry Key Immobilizer Module Replacement REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Removal. 3. Remove the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Removal. Fig.15 Sentry Key Immobilizer Module (SKIM) Remove/Install 4. Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). 5. Remove the two screws securing the SKIM to the top of the steering column. 6. Rotate the SKIM and its mounting bracket upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKIM from the vehicle. INSTALLATION NOTE: If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/SENTRY KEY IMMOBILIZER MODULE STANDARD PROCEDURE). 1. Place the SKIM into position. 2. Rotate the SKIM and its mounting bracket downwards and then to the side towards the steering column. 3. Install the two screws securing the SKIM to the top of the steering column. 4. Engage the steering column wire harness to the Sentry Key Immobilizer Module (SKIM). 5. Install the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Installation. 6. Install the Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Installation. 7. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6377 Alarm Module: Service and Repair Programming the Sentry Key Immobilizer Module PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. 1. Turn the ignition on (transmission in park/neutral). 2. Use the DRBIII and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select SKIM MODULE REPLACEMENT (GASOLINE). 4. Program the vehicle four-digit PIN into the SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select UPDATE VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the VIN (the PCM will send the VIN to the SKIM). 8. The DRBIII will ask if you want to transfer the secret key. Select ENTER to transfer secret key from the PCM. This will ensure the current vehicle ignition keys will still operate the SKIS system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6378 Alarm Module: Service and Repair Programming Ignition Keys to the Sentry Key Immobilizer Module PROGRAMMING IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE 1. Turn the ignition on (transmission in Park / Neutral). 2. Use the DRBIII and select THEFT ALARM, SKIM, then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEYS. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM AT ONE TIME. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRBIII will display one of the following messages: Programming Not Attempted - The DRBIII attempts to read the programmed key status and there are no keys programmed in the SKIM memory. Programming Key Failed - (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done - SKIM transponder ID memory is full. 1. Obtain ignition keys to be programmed from customer (8 keys maximum) 2. Using the DRBIII, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS 3. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6379 Alarm Module: Service and Repair Sentry Key Immobilizer System Initialization The Sentry Key Immobilizer System (SKIS) initialization should be performed following a Sentry Key Immobilizer Module (SKIM) replacement. It can be summarized as follows: 1. Obtain the vehicle's unique four-digit PIN assigned to its original SKIM from the vehicle owner, the vehicle's invoice, or from Chrysler's Customer Center. 2. Using a DRB III scan tool, select "Theft Alarm," "SKIM," "Miscellaneous," and then "SKIM Module Replaced." a. Enter Secured Access Mode using the unique four-digit PIN. b. Program the vehicle's VIN number into the SKIM's memory. c. Program the country code into the SKIM's memory (for North America, choose US or domestic). d. The vehicle's unique Secret Key data will be retrieved from the PCM automatically. If this data is corrupt or not present, you will be prompted to cut new keys for this vehicle. 3. Program all customer keys into the SKIM's memory. This process will require that the SKIM to be in the Secured Access Mode. The PIN must be entered into the DRB III scan tool before the SKIM will enter the Secured Access Mode. Once entered, Secured Access Mode shall be active until 60 seconds after the last command requiring secured access was received and acknowledged. Two exceptions to this rule are: - When you have used the 'erase all keys' command OR - When you have just programmed a new key. If either of these functions are performed successfully while in the Secured Access Mode, this mode will be exited immediately following the function. NOTE: If a PCM is replaced, the unique 'Secret Key' data must be transferred from the SKIM to the new PCM using the PCM replacement procedure. This procedure requires the Secured Access Mode as well and can be found in the DRB III scan tool. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6380 Alarm Module: Service and Repair PCM/SKIM Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6381 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Sentry Key Immobilizer Transponder TRANSPONDER KEY The Sentry Key Immobilizer System (SKIS) uses a transponder chip that is integral to each ignition key to communicate with the Sentry Key Immobilizer Module (SKIM). Ignition keys are supplied with the vehicle when it is shipped from the factory The transponder chip is undermolded within the head of the key. This undermold is hidden beneath an overmolded rubber cap. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique "Secret Key" code programmed into it by the manufacturer as well. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the "Secret Key" code from the SKIM. Once the Sentry Key learns the "Secret Key" code of the SKIM, it is also permanently programmed into the transponder's memory Therefore, blank keys for the SKIS must be programmed by the SKIM in addition to being cut to match the mechanical coding of the ignition lock cylinder. Refer to Electrical, Vehicle Theft Security Transponder Key, Standard Procedure - Transponder Programming. The Sentry Key's transponder is within the range of the SKIM's transceiver antenna ring when it is inserted into the ignition lock cylinder. When the ignition switch is turned to the ON position, the SKIM communicates with the Sentry Key via a radio frequency (RF) signal. The SKIM determines if a valid key is present based on the information it receives from the Sentry Key. If a valid key is detected, that fact is communicated to the PCM via the PCI bus and the vehicle is allowed to continue running. If an invalid key is received by the PCM or no status at all is communicated, the vehicle will stall after two (2) seconds of running. The indicator light will be flashing at this point. The Sentry Key's transponder can not be repaired. If it is faulty or damaged, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 6385 Alarm System Transponder: Service and Repair TRANSPONDER PROGRAMMING Using a DRB III Scan Tool All Sentry Keys included with the vehicle are preprogrammed to work with the Sentry Key Immobilizer System (SKIS) when it is shipped from the factory. The Sentry Key Immobilizer Module (SKIM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition lock cylinder of the vehicle for which it will be used. The vehicle's four digit PIN code will be required to complete this task since you will need it to enter the Secured Access Mode in the SKIM. The following steps must be completed using a DRB III scan tool: 1. Insert the blank key into the ignition and turn it to the RUN position. 2. Using a DRB III scan tool, select "Theft Alarm," "SKIM," "Miscellaneous," and then "Program Ignition Key." 3. Enter the four digit PIN code using the DRB III scan tool. When programming is completed, the SKIM will exit Secured Access Mode and the DRB III scan tool will display the results of your attempt to program the key. One of five distinct results may be displayed. All five are listed below: - "Programming Successful" is displayed if the Sentry Key programming is successful. - "Learned Key in Ignition" is displayed if the key in the ignition has already been programmed into that vehicle's SKIM. - "Eight Keys Already Learned (At The Maximum) Programming Not Done" is displayed if eight keys have already been programmed into the SKIM. In this case, if a new key needs to be added due to a lost or defective key, the "Erase All Keys" command (which requires entering the Secured Access Mode) has to be performed. Following the "Erase All Keys" command, all keys that will be used to operate the vehicle MUST be reprogrammed to the SKIM. - "Programming Not Attempted" is displayed after an "Erase All Keys" function is executed. - "Programming Key Failed" is displayed if further diagnosis is required. To learn additional keys, turn the ignition OFF, remove the learned key, insert the next new blank key, and repeat the steps from the beginning. "Customer Learn" Mode This feature is only available on domestic vehicles or those which have a U.S. country code designator. This procedure requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, Sentry Key programming will require the use of a DRB III scan tool. The steps required to program Sentry Keys with two valid Sentry Keys follows: 1. Obtain the blank Sentry Key(s) that need to be programmed. Cut the keys to match the ignition lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. 3. After the ignition switch has been in the ON position for longer than three seconds, but no more than fifteen seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted, and the ignition key to the ON position, within 15 seconds of removing the first valid Sentry key. 4. About 10 seconds after the completion of Step 3, the indicator light will start to flash and a single audible chime tone will sound to indicate that the system has entered the "Customer Learn" programming mode. 5. Within 60 seconds of entering the "Customer Learn" programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. 6. About 10 seconds after the completion of Step 5, a single audible chime tone will sound and the indicator light will stop flashing and stay on solid for three (3) seconds and then turn off to indicate that the blank Sentry Key has been successfully programmed. The SKIS will immediately exit the "Customer Learn" programming mode and the vehicle may be started using the newly programmed Sentry Key. These steps must be completed in their entirety for each additional Sentry Key to be programmed. If any of the above steps are not completed in the given sequence, or within the allotted time, the SKIS will exit the "Customer Learn" programming mode and the programming will be unsuccessful. The SKIS will also automatically exit the "Customer Learn" programming mode if: It sees a non-blank Sentry Key when it should see a blank. - If it has already programmed eight (8) valid Sentry Keys. - If the ignition switch is turned to the OFF position for more than about 50 seconds. NOTE: If you attempt to start the vehicle while in "Customer Learn" mode (LED flashing), the vehicle will behave as though an invalid key is being used (i.e. the engine will stall after two (2) seconds of running). No faults will be logged. NOTE: Once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6389 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH (EXPORT) REMOVAL 1. Open hood. Fig.1 Battery Negative Cable - Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Disconnect wire harness connector from hood ajar switch. Fig.2 Hood Ajar Switch Location 4. Firmly press tangs on the bottom side of the switch together and push up through bracket. 5. Remove switch from vehicle. INSTALLATION 1. Firmly press hood ajar switch through bracket. 2. Connect wire harness connector to hood ajar switch. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Testing and Inspection Ignition Key In Signal: Testing and Inspection KEY LEFT IN IGNITION To test the key left in ignition function, insert key into the ignition and open the driver's door. Chime should sound until key is removed from ignition or driver's door is closed. If these conditions are met and there is still a problem with the system, refer to Electrical, Chime/Buzzer, Diagnosis and Testing - Chime System Conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6402 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6408 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6411 Keyless Entry Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6412 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6413 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6414 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6415 Remote Keyless Entry Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6416 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE There are 2 Remote Keyless Entry Modules for the 2002 module year, premium and base. The base module is for a vehicle with power door locks only. The base module performs the same functions that the premium module does but has no provisions for Vehicle Theft Security System (VTSS) or Remote Keyless Entry. Both modules communicate with other modules via the PCI bus circuit. The module monitors the Airbag Control Module messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message, along with the verification that the ignition is on, it will provide the "enhanced accident response feature". This feature will cause the module to unlock all doors and the instrument cluster to turn the courtesy lamps ON. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message and receive body style information. The Base module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the driver or passenger (BUX) cylinder lock switch. The premium module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the RKE transmitter. Two RKE transmitters are supplied with a premium equipped vehicle but a total of 4 can be programmed to the module. Horn chirp on a premium equipped vehicle is customer programmable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6417 Keyless Entry Module: Testing and Inspection For procedures on diagnosing and testing the RKE Module's RKE functions, refer to the proper Body Diagnostic Procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation Fig.1 Remote Keyless Entry Transmitter The Remote Keyless Entry (RKE) system Radio Frequency (RF) transmitter is equipped with four buttons, labeled LOCK, UNLOCK, DECK LID RELEASE, and PANIC. It is also equipped with a key ring and is designed to serve as a key fob. The operating range of the transmitter radio signal is up to 10 meters (30 feet) from the RKE receiver. Each RKE transmitter has a different vehicle access code, which must be programmed into the memory of the RKE receiver in the vehicle in order to operate the RKE system. Two transmitters are provided with the vehicle, but the RKE receiver can retain the access codes of up to four transmitters in its memory. The RKE transmitter operates on two Panasonic CR2016 (or equivalent) batteries. Typical battery life is from one to two years. The RKE transmitter cannot be repaired and, if faulty or damaged, it must be replaced. The transmitter has four buttons for operation. They are LOCK, UNLOCK, DECK LID RELEASE, and PANIC. - The UNLOCK button will unlock the driver's door, flash the park lamps twice and enable illuminated entry. Pushing and releasing the button once will unlock the driver's door. Pushing and releasing the button two times, within a five second interval, will unlock all doors. - Upon pressing the LOCK button, the horn will sound a short CHIRP (if enabled) and flash the park lamps to notify that the all door lock signal was received and set. Illuminated entry is cancelled and the interior lamps are faded to OFF. - Pushing and releasing the DECK LID RELEASE button two times within a five second interval, will slightly ajar the deck lid. - Pushing and holding the PANIC button will cause the panic alarm to sound for three minutes, until the panic button is pressed and held a second time, or the vehicle reaches a speed of 15 mph. The receiver is capable of retaining a Vehicle Access Code (VAC) even when power is removed. Each Remote Keyless Entry (RKE) module must have at least one and no more than four transmitters. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming Keyless Entry Transmitter: Service and Repair Transmitter Programming STANDARD PROCEDURE - TRANSMITTER PROGRAMMING The Remote Keyless Entry transmitters can be programmed with the use of the DRB III scan tool or by the customer. DRB III Programming When Using The DRB III Scan Tool, SELECT: 1. "Theft Alarm" 2. "VTSS" 3. "Miscellaneous" and then the desired function. Customer Programming For a customer to be able to program RKE transmitters themselves, at least one RKE transmitter must be programmed already This procedure is to add additional transmitters. If all transmitters are lost, the DRB III scan tool must be used to program the new transmitters. 1. Insert the key into the ignition switch, and turn the ignition switch to the RUN position (without starting the vehicle). 2. Using the RKE transmitter programmed to the RKE module, press and continuously hold down the UNLOCK button for 4 - 10 seconds. 3. Within the 4 10 second time range, continue to hold the UNLOCK button and press the PANIC button. Both buttons may then be released. Upon the PANIC button being depressed, the message for customer programming mode will be transmitted to the RKE module. 4. A chime will be heard to verify that the customer programming mode has been entered. 5. Press and release any button on each transmitter that is to be programmed to the RKE module, including any transmitters which were previously programmed to the RKE module (with a maximum of four possible). After each transmitter is successfully programmed, a chime will be heard to verify that successful programming of the transmitter has occurred. 6. After 30 seconds, or upon the ignition switch being turned OFF, a chime will indicate that the RKE module has exited the programming mode. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 6423 Keyless Entry Transmitter: Service and Repair Keyless Entry Transmitter Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Disconnect wire connector. 4. Remove two attaching screws. 5. Remove the switch from the door panel. INSTALLATION 1. Install the switch to the door panel. 2. Install the two attaching screws. 3. Connect the one wire connector. 4. Install the front door trim panel. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 6428 Lock Cylinder Switch: Connector Locations Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 6429 Fig. 45 Door (Passenger) - RHD Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 6430 Lock Cylinder Switch: Diagrams Right Cylinder Lock Switch (Export) Left Cylinder Lock Switch (Premium) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 6431 Lock Cylinder Switch: Service and Repair DOOR CYLINDER LOCK SWITCH REMOVAL 1. Remove the door trim panel. Refer to Body, Door - Front, Trim Panel, Removal. 2. Remove the illuminated entry switch wiring clip and disconnect connector. 3. Remove door cylinder lock switch from door handle. INSTALLATION 1. Install the door cylinder lock switch from door handle. 2. Install the illuminated entry switch wiring clip and disconnect connector. 3. Install the door trim panel. Refer to Body, Door - Front, Trim Panel, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Application and ID Security Lamp/Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Security Alarm Indicator ...................................................................................................................... ................................................................. LED All the interior bulbs are brass or glass wedge base. Aluminum base bulbs are not approved and should not be used for replacement. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Application and ID > Page 6435 Security Lamp/Indicator: Description and Operation SKIS INDICATOR LAMP The Sentry Key Immobilizer System (SKIS) uses the Vehicle Theft Security System (VTSS) indicator LED to give an indication when the SKIS is faulty or when the vehicle has been immobilized due to the use of an invalid ignition key. The LED is controlled by the instrument cluster circuitry based upon messages received from the Sentry Key Immobilizer Module (SKIM). The SKIM sends messages to the instrument cluster, to turn the LED on for about three seconds when the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends PCI bus messages to keep the LED off for a duration of about one second. Then the SKIM sends messages to the instrument cluster circuitry to turn the LED on or off based upon the results of the SKIS self-tests. If the VTSS indicator LED comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the ON position, it sends messages to the instrument cluster to flash the VTSS indicator LED. The SKIM can also send messages to the instrument cluster to flash the LED and to generate a single audible chime tone. These functions serve as an indication to the customer that the SKIS has been placed in its "Customer Learn" programming mode. See Sentry Key Immobilizer System Transponder Programming in this group for more information on the "Customer Learn" programming mode. The VTSS indicator LED uses a Light Emitting Diode (LED) on the instrument cluster electronic circuit board. It is not serviceable separate from the instrument cluster assembly. If the VTSS indicator LED comes on and stays on after the bulb test function, diagnosis of the SKIS should be performed with a DRB III scan tool and the proper Powertrain Diagnostic Procedures manual. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 6440 Fig. 48 Decklid - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Page 6441 Decklid Security Switch (Knock Out) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Page 6442 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair DECKLID SECURITY SWITCH REMOVAL The Vehicle Theft Security System (VTSS) Deck Lid Security Switch is mounted to the back of the deck lid lock cylinder. 1. Open deck lid. 2. Disconnect wire connector to switch. 3. Remove the spring clip retainer. 4. Pull switch off of deck lid lock cylinder and remove from vehicle. INSTALLATION 1. Push switch onto the deck lid lock cylinder. 2. Install the spring clip retainer. 3. Connect the wire connector to switch. 4. Close the deck lid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions Intrusion Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Intrusion Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Domelamp / Intrusion Sensor (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Intrusion Sensor: Electrical Diagrams PLEASE NOTE: Some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-39-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 8w-39-3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 8w-39-4 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 8w-39-5 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 8w-39-6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 8w-39-7 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 8w-39-8 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 8w-39-9 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 8w-39-10 (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 8w-39-11 (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 8w-39-12 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 8w-39-13 (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 8w-39-14 (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 8w-39-15 (Export) NOTE: Other diagrams referred to by number (8W-70-2, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 6486 Intrusion Sensor: Description and Operation ULTRASONIC INTRUSION SENSOR Fig.3 VTSS Intrusion Sensor Some vehicles equipped with the premium Vehicle Theft Security System (VTSS) use a ultrasonic intrusion sensor. This intrusion sensor is integrated into the dome lamp and detects any movement in the cabin when the VTSS system and the intrusion sensor are armed The sensor cannot be serviced separately and if found to be faulty the entire dome lamp assembly must be replaced In the event the intrusion sensor detects movement inside the vehicle's interior (with system armed), the ARKEM module will sound the siren. DISARMING THE INTRUSION SENSOR - Press the "LOCK" button on Remote Keyless Entry transmitter THREE times within five (5) seconds This operation must be performed during the first 16 seconds of VTSS system arming - Rotating the drivers door key cylinder THREE times within five (5) seconds This operation must be performed during the first 16 seconds of VTSS system arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 6487 Intrusion Sensor: Service and Repair ULTRASONIC INTRUSION SENSOR REMOVAL 1. Disconnect and isolate the negative battery cable Fig.4 Dome Lamp Unit With Intrusion Sensor Removal 2. Grasp the dome lamp unit with intrusion sensor and rotate counterclockwise. 3. Pull straight down on dome lamp unit with intrusion sensor. 4. Disconnect electrical connector. 5. Remove the dome lamp unit with intrusion sensor from the vehicle INSTALLATION 1. Connect electrical connector Fig.5 Dome Lamp Unit With Intrusion Sensor Orientation To Headliner Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 6488 2. Orient the dome lamp unit with intrusion sensor in a way that the tabs align with the slots in the headliner. 3. Push the dome lamp unit with intrusion sensor straight up. 4. Rotate the dome lamp unit with intrusion sensor clockwise. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams Compact Disc Changer Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 6494 CD Changer: Description and Operation CD CHANGER The In-Dash CD Changer (if equipped) is located in the instrument panel below the radio The remote changer does not use a cartridge or magazine for the CD's Up to 6 CD's (4 in some export markets) can be directly loaded into this unit, one at a time Due to its compact design, the CD changer can carry out only one operation at a time For example, you can not load a new disc while playing another at the same time Each operation happens sequentially The radio unit provides control over all features of the CD changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD changer All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD changer information on the radio display. The CD changer contains a Load/Eject button and an indicator LED for each of the disc positions as well as an illuminated disc opening. The individual LED indicates whether a CD is currently loaded or ready to load in that particular chamber of the CD changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 6495 CD Changer: Service and Repair CD CHANGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755), gently pry out on CD changer bezel and remove. Fig.3 CD Changer Remove/Install 3. Remove two retaining screws to CD changer. 4. Pull CD changer out of instrument panel and disconnect harness connector from rear of changer. 5. Remove CD changer from vehicle. INSTALLATION 1. Connect harness connector to CD changer. 2. Install CD changer to vehicle. 3. Install retaining screws. 4. Install CD changer bezel. 5. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation Radio/Stereo Noise Filter: Description and Operation RADIO NOISE SUPPRESSION COMPONENTS The vehicle has the following noise suppression components which, if disconnected, may interfere with radio reception: Cylinder head to body ground strap (Y-strap). - Battery tray to transmission ground strap (automatic transmission only). - Hood hinge straps (left and right). - Noise suppression capacitor. - Strut to body ground straps (left and right). Resistive type spark plug cables in the high tension circuit of the ignition system complete the interference suppression. Faulty or deteriorated spark plug wires should be replaced. There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and Electro-Magnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Left Front Door Speaker Left Instrument Panel Speaker Left Rear Speaker Right Front Door Speaker Right Instrument Panel Speaker Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6503 Right Rear Speaker Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6504 Speaker: Description and Operation SPEAKERS The standard equipment speaker system includes speakers in six locations. One 2.5 centimeter (1.0 in.) diameter speaker is installed on each end of the instrument panel top pad. One 16.5 centimeter (6.5 in.) full-range speaker is located in each front door. There is also two full-range 15.2 X 22.8 centimeter (6 X 9 in.) diameter full-range speakers located in the rear shelf. Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6505 Speaker: Testing and Inspection SPEAKER DIAGNOSIS Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. If all speakers are inoperative, check the fuses in the fuse block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 3. 3. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. Remove the radio receiver. 4. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 5. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door Speaker: Service and Repair Speaker Replacement - Front Door FRONT DOOR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. Fig.6 Front Door Speaker Remove/Install 3. Remove speaker retaining screws. 4. Remove speaker assembly and disconnect wire connector from rear of speaker. INSTALLATION 1. Connect wire connector to speaker and install speaker to vehicle. 2. Install speaker retaining screws. 3. Install front door trim panel. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door > Page 6508 Speaker: Service and Repair Speaker Replacement - Instrument Panel INSTRUMENT PANEL REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Fig.7 Instrument Panel Speakers Remove/Install 3. Remove speaker retaining screws. 4. Remove speaker and disconnect wire connector. INSTALLATION 1. Connect wire harness to the speaker and install speaker to instrument panel. 2. Install speaker retaining screws. 3. Install instrument panel top cover. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Door > Page 6509 Speaker: Service and Repair Speaker Replacement - Rear REAR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove Rear Seat Cushion. 3. Remove rear seat back. 4. Remove rear shelf panel. Fig.8 Rear Shelf Speaker(s) Remove/Install 5. Remove four speaker retaining screws. 6. Remove speaker and disconnect wire connector. 7. Remove speaker(s) from vehicle. INSTALLATION 1. Connect wire connector to the speaker. 2. Install speaker to the vehicle. 3. Install speaker retaining screws. 4. Install rear shelf panel. 5. Install seat back. 6. Install rear seat cushion. 7. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Alarm Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6519 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Alarm Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6525 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations Fig.9 Sentry Key Immobilizer Module (SKIM) Location Sentry Key Immobilizer Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 6528 Alarm Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 6529 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6530 Sentry Key Immobilizer Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6531 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE (SKIM) Fig.13 Sentry Key Immobilizer Module Fig.14 Sentry Key Immobilizer Module Location The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the instrument cluster, and the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique "Secret Key" code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The "Secret Key" code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the "Secret Key" code can be restored from the PCM by following the SKIM replacement procedure found in the DRB III scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original "Secret Key" code can not be recovered, new ignition keys will be required. The DRB III scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6532 secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the PCM during initialization. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an "invalid key" message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is "invalid key." Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. The SKIM also sends indicator light status messages to the instrument cluster to tell that module how to operate the light. This may consist of turning the light ON for a three (3) second bulb test when the ignition switch is first turned to the ON position. It is also the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement Alarm Module: Service and Repair Sentry Key Immobilizer Module Replacement REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Removal. 3. Remove the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Removal. Fig.15 Sentry Key Immobilizer Module (SKIM) Remove/Install 4. Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). 5. Remove the two screws securing the SKIM to the top of the steering column. 6. Rotate the SKIM and its mounting bracket upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKIM from the vehicle. INSTALLATION NOTE: If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/SENTRY KEY IMMOBILIZER MODULE STANDARD PROCEDURE). 1. Place the SKIM into position. 2. Rotate the SKIM and its mounting bracket downwards and then to the side towards the steering column. 3. Install the two screws securing the SKIM to the top of the steering column. 4. Engage the steering column wire harness to the Sentry Key Immobilizer Module (SKIM). 5. Install the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Installation. 6. Install the Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Installation. 7. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6535 Alarm Module: Service and Repair Programming the Sentry Key Immobilizer Module PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE NOTE: If the PCM and the SKIM are replaced at the same time, program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKIM. 1. Turn the ignition on (transmission in park/neutral). 2. Use the DRBIII and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select SKIM MODULE REPLACEMENT (GASOLINE). 4. Program the vehicle four-digit PIN into the SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select UPDATE VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the VIN (the PCM will send the VIN to the SKIM). 8. The DRBIII will ask if you want to transfer the secret key. Select ENTER to transfer secret key from the PCM. This will ensure the current vehicle ignition keys will still operate the SKIS system. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6536 Alarm Module: Service and Repair Programming Ignition Keys to the Sentry Key Immobilizer Module PROGRAMMING IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE 1. Turn the ignition on (transmission in Park / Neutral). 2. Use the DRBIII and select THEFT ALARM, SKIM, then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEYS. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM AT ONE TIME. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRBIII will display one of the following messages: Programming Not Attempted - The DRBIII attempts to read the programmed key status and there are no keys programmed in the SKIM memory. Programming Key Failed - (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done - SKIM transponder ID memory is full. 1. Obtain ignition keys to be programmed from customer (8 keys maximum) 2. Using the DRBIII, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS 3. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6537 Alarm Module: Service and Repair Sentry Key Immobilizer System Initialization The Sentry Key Immobilizer System (SKIS) initialization should be performed following a Sentry Key Immobilizer Module (SKIM) replacement. It can be summarized as follows: 1. Obtain the vehicle's unique four-digit PIN assigned to its original SKIM from the vehicle owner, the vehicle's invoice, or from Chrysler's Customer Center. 2. Using a DRB III scan tool, select "Theft Alarm," "SKIM," "Miscellaneous," and then "SKIM Module Replaced." a. Enter Secured Access Mode using the unique four-digit PIN. b. Program the vehicle's VIN number into the SKIM's memory. c. Program the country code into the SKIM's memory (for North America, choose US or domestic). d. The vehicle's unique Secret Key data will be retrieved from the PCM automatically. If this data is corrupt or not present, you will be prompted to cut new keys for this vehicle. 3. Program all customer keys into the SKIM's memory. This process will require that the SKIM to be in the Secured Access Mode. The PIN must be entered into the DRB III scan tool before the SKIM will enter the Secured Access Mode. Once entered, Secured Access Mode shall be active until 60 seconds after the last command requiring secured access was received and acknowledged. Two exceptions to this rule are: - When you have used the 'erase all keys' command OR - When you have just programmed a new key. If either of these functions are performed successfully while in the Secured Access Mode, this mode will be exited immediately following the function. NOTE: If a PCM is replaced, the unique 'Secret Key' data must be transferred from the SKIM to the new PCM using the PCM replacement procedure. This procedure requires the Secured Access Mode as well and can be found in the DRB III scan tool. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6538 Alarm Module: Service and Repair PCM/SKIM Programming PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC) 2. Program the new SKIM 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading . Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done -SKIM transponder ID memory is full. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module Replacement > Page 6539 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN.KEYS. 7. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6548 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 6554 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6557 Keyless Entry Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6558 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6559 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 6560 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6561 Remote Keyless Entry Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6562 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE There are 2 Remote Keyless Entry Modules for the 2002 module year, premium and base. The base module is for a vehicle with power door locks only. The base module performs the same functions that the premium module does but has no provisions for Vehicle Theft Security System (VTSS) or Remote Keyless Entry. Both modules communicate with other modules via the PCI bus circuit. The module monitors the Airbag Control Module messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message, along with the verification that the ignition is on, it will provide the "enhanced accident response feature". This feature will cause the module to unlock all doors and the instrument cluster to turn the courtesy lamps ON. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message and receive body style information. The Base module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the driver or passenger (BUX) cylinder lock switch. The premium module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the RKE transmitter. Two RKE transmitters are supplied with a premium equipped vehicle but a total of 4 can be programmed to the module. Horn chirp on a premium equipped vehicle is customer programmable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6563 Keyless Entry Module: Testing and Inspection For procedures on diagnosing and testing the RKE Module's RKE functions, refer to the proper Body Diagnostic Procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6568 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH (EXPORT) REMOVAL 1. Open hood. Fig.1 Battery Negative Cable - Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Disconnect wire harness connector from hood ajar switch. Fig.2 Hood Ajar Switch Location 4. Firmly press tangs on the bottom side of the switch together and push up through bracket. 5. Remove switch from vehicle. INSTALLATION 1. Firmly press hood ajar switch through bracket. 2. Connect wire harness connector to hood ajar switch. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 6573 Lock Cylinder Switch: Connector Locations Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 6574 Fig. 45 Door (Passenger) - RHD Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6575 Lock Cylinder Switch: Diagrams Right Cylinder Lock Switch (Export) Left Cylinder Lock Switch (Premium) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6576 Lock Cylinder Switch: Service and Repair DOOR CYLINDER LOCK SWITCH REMOVAL 1. Remove the door trim panel. Refer to Body, Door - Front, Trim Panel, Removal. 2. Remove the illuminated entry switch wiring clip and disconnect connector. 3. Remove door cylinder lock switch from door handle. INSTALLATION 1. Install the door cylinder lock switch from door handle. 2. Install the illuminated entry switch wiring clip and disconnect connector. 3. Install the door trim panel. Refer to Body, Door - Front, Trim Panel, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Locations Road Temperature Sensor: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Locations > Page 6580 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 6585 Fig. 48 Decklid - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Page 6586 Decklid Security Switch (Knock Out) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations > Page 6587 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair DECKLID SECURITY SWITCH REMOVAL The Vehicle Theft Security System (VTSS) Deck Lid Security Switch is mounted to the back of the deck lid lock cylinder. 1. Open deck lid. 2. Disconnect wire connector to switch. 3. Remove the spring clip retainer. 4. Pull switch off of deck lid lock cylinder and remove from vehicle. INSTALLATION 1. Push switch onto the deck lid lock cylinder. 2. Install the spring clip retainer. 3. Connect the wire connector to switch. 4. Close the deck lid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions Intrusion Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Intrusion Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Domelamp / Intrusion Sensor (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Intrusion Sensor: Electrical Diagrams PLEASE NOTE: Some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-39-2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 8w-39-3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 8w-39-4 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 8w-39-5 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 8w-39-6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 8w-39-7 (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 8w-39-8 (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 8w-39-9 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 8w-39-10 (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 8w-39-11 (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 8w-39-12 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 8w-39-13 (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 8w-39-14 (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 8w-39-15 (Export) NOTE: Other diagrams referred to by number (8W-70-2, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 6631 Intrusion Sensor: Description and Operation ULTRASONIC INTRUSION SENSOR Fig.3 VTSS Intrusion Sensor Some vehicles equipped with the premium Vehicle Theft Security System (VTSS) use a ultrasonic intrusion sensor. This intrusion sensor is integrated into the dome lamp and detects any movement in the cabin when the VTSS system and the intrusion sensor are armed The sensor cannot be serviced separately and if found to be faulty the entire dome lamp assembly must be replaced In the event the intrusion sensor detects movement inside the vehicle's interior (with system armed), the ARKEM module will sound the siren. DISARMING THE INTRUSION SENSOR - Press the "LOCK" button on Remote Keyless Entry transmitter THREE times within five (5) seconds This operation must be performed during the first 16 seconds of VTSS system arming - Rotating the drivers door key cylinder THREE times within five (5) seconds This operation must be performed during the first 16 seconds of VTSS system arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 6632 Intrusion Sensor: Service and Repair ULTRASONIC INTRUSION SENSOR REMOVAL 1. Disconnect and isolate the negative battery cable Fig.4 Dome Lamp Unit With Intrusion Sensor Removal 2. Grasp the dome lamp unit with intrusion sensor and rotate counterclockwise. 3. Pull straight down on dome lamp unit with intrusion sensor. 4. Disconnect electrical connector. 5. Remove the dome lamp unit with intrusion sensor from the vehicle INSTALLATION 1. Connect electrical connector Fig.5 Dome Lamp Unit With Intrusion Sensor Orientation To Headliner Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Intrusion Sensor <--> [Ultrasonic Sensor, Antitheft] > Component Information > Diagrams > Page 6633 2. Orient the dome lamp unit with intrusion sensor in a way that the tabs align with the slots in the headliner. 3. Push the dome lamp unit with intrusion sensor straight up. 4. Rotate the dome lamp unit with intrusion sensor clockwise. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information Towing Information: Technician Safety Information STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 6639 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 6640 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 6641 Towing Information: Vehicle Damage Warnings STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 6642 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 6643 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Road Temperature Sensor > Component Information > Locations Road Temperature Sensor: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Road Temperature Sensor > Component Information > Locations > Page 6648 Fig. 36 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Body Control Module: Electrical Diagrams Airbag System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Audio System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 CD Changer Compass/Temperature Mirror Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Exterior Lighting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Instrument Cluster Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Interior Lighting Power Door Locks/RKE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Vehicle Communication Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 6689 Body Control Module: Vehicle Damage Warnings Electrical Testing 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description Identification Of System The vehicle systems that are part of the "body" system are: - Airbag System - Audio - Compass/Temperature Mirror - Instrument Cluster - Interior Lighting - Power Door Locks/Remote Keyless Entry - Vehicle Communications - Vehicle Theft Security System System Description The body system on the 2003 PL consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Vehicle Communication See: Functional Operation/Vehicle Communication of this general information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6692 Body Control Module: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. DRIVER AIRBAG (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation, The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6693 PASSENGER AIRBAG (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. WARNING: THE AIRBAG INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN ADDITION, THE PASSENGER AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). WARNING: REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. SIDE IMPACT AIRBAG CONTROL MODULES (SIACM) They are located on the left and right B-post. The SIACM perform self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ACM once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned on. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. NOTE: When the Airbag Warning Indicator is illuminated, interrogate the ACM. SEAT AIRBAGS The Left and Right seat airbag modules are located in the outboard end of the front seat backs. The airbag module contains a bag, an inflator (a small canister of highly compressed argon gas) and a mounting bracket. The seat airbag module cannot be repaired and must be replaced if deployed or in any way damaged. When supplied with the proper electrical signal the inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion. Upon deployment, the seat back trim cover will tear open and allow the seat airbag to fully deploy between the seat and the door. NOTE: It will be necessary to remove the seat back trim to gain access to the seat airbag module connector when diagnosing the seat airbag system. WARNING: THE SEAT AIRBAG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SPECIAL TOOLS Some airbag diagnostic tests use special tools, 8310 and 8443 airbag load tool, for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6694 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: * Erase the stored codes * Place the ignition in the Run position * Wiggle the wire harness and connectors * Rotate the steering wheel from stop to stop * Recheck for active codes periodically as you work through the system. Audio System AUDIO SYSTEM The audio system on the 2003 PL consists of a radio that communicates over the PCI bus. The speakers are located in the instrument panel, the front doors and the rear "D" pillars. The instrument panel speakers are a tweeter type speaker for high frequency. The front door speakers are a woofer/midrange type speaker. The rear "D" pillar speakers are a full range type speaker. If one of the speaker circuits experiences a short, the other speakers on that output channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which the DRB III(R) can display. The in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect , such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in the chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6695 disc in that chamber. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Compass/Temperature Mirror COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6696 Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6697 magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6698 If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Exterior Lighting EXTERIOR LIGHTING The Headlamps are controlled by the Instrument Cluster. The Instrument Cluster is also referred to as a "Smart Cluster". It receives and sends messages to other modules through the PCI BUS circuit. The Headlamps are wired through the cluster and then go to the Fuse Block to the lamps. Each Headlamp has an independent fuse located in the Fuse Block. For vehicles equipped with Daytime Running Lamps, the DRL Module is integrated with the Instrument Cluster. Interior Lighting INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. Some of the features that it controls are the courtesy lamps, chime, and all instrument illumination. It receives and sends messages to other modules via the PCI bus circuit. The front turn signals are wired through the cluster and then go to the front lamps. For vehicles equipped with Daytime Running Lamps, the DRL module is built into the cluster. Power Door Locks/Remote Keyless Entry REMOTE KEYLESS ENTRY MODULE The Remote Keyless Entry module controls the Power Door Locks and the Vehicle Theft Security System (VTSS). It also wakes up the Instrument Cluster to turn on the illuminated entry when it senses a signal from the RKE transmitter. The module communicates with other modules via the PCI bus circuit. The RKE module monitors the Occupant Restraint Controller messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message along with the verification that the ignition is on and the vehicle speed is zero, it will provide the "enhanced accident response feature". This feature will cause the module to unlock-all doors immediately and the instrument cluster to turn the courtesy lamps on when the vehicle reaches 0 mph. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message, and receive body style information. Two transmitters are supplied with the vehicle but a total of 4 can be programmed to the module. The horn chirp on vehicle lock command is customer programmable. To limit the amount of battery drain during storage, the IOD fuse may be removed. VEHICLE THEFT SECURITY SYSTEM When the VTSS is armed, it will monitor the ignition switch status, ajar switches for the vehicle doors and decklid. Also monitored is a decklid security switch (knockout) for the cylinder lock. If the alarm is tripped, it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6699 Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, by using the driver door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of an open decklid security switch sense circuit. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with the driver door cylinder lock. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. VEHICLE THEFT SECURITY SYSTEM (Export Only) When the VTSS is armed, it Will monitor the interior of the vehicle for movement via an intrusion sensor (if equipped), the ignition switch status, ajar switches for the vehicle doors, decklid and hood. Vehicles without an intrusion sensor will have a decklid security switch (knockout) which will also be monitored. If the alarm is tripped, it will sound the vehicles horn or a battery backed siren for vehicles equipped with the intrusion sensor, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Arming the system is accomplished by locking the doors with the door lock switch following a normal exit sequence of opening the door pressing the power lock button and closing the door, or by using either door cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if the RKE module receives an unlock request the system will automatically be disarmed. If the VTSS indicator stays on steady during prearm, it is an indication of the hood ajar circuit being shorted (hood opened) or the decklid security switch circuit being open (if equipped). Defeating the intrusion sensor feature for vehicles so equipped can be done by three additional lock request to the RKE module within 5 seconds. Disarming is done by either a RKE unlock or turning the ignition on with a valid Sentry key. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful to determine the cause of a customer complaint of the alarm going off with no apparent reason. Vehicle Communication VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2003 PL: - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio (If equipped) - CD Changer (If equipped) - Compass/Temperature Mirror (If equipped) - Remote Keyless Entry Module (If equipped) - Sentry Key Immobilizer Module (If equipped) - Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6700 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III(R) lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the diagram for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at the module, or an open battery or ground circuit to the affected Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - No response received from any module on the PCI bus (except PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III(R). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 6701 Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III(R) may display "BUS +A SIGNALS OPEN" OR "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2003 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for Daimler/Chrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. New Diagnostic procedures and New DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Airbag Indicator On Without ACM Trouble Codes Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACM TROUBLE CODES POSSIBLE CAUSES - Airbag indicator on without ACM trouble codes - Instrument cluster problems No Response From Airbag Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6704 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6705 Test 3 - 4 SYMPTOM NO RESPONSE FROM ACM POSSIBLE CAUSES - Checking for voltage at ACM - Ground circuit open - PCI bus circuit open - Airbag control module AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6706 POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6707 CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6708 Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure No Response From Radio Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6709 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6710 Test 4 - 6 SYMPTOM NO RESPONSE FROM RADIO POSSIBLE CAUSES - No response from radio - Open fused ignition switch output circuit - Open fused B+ circuit - Radio ground circuit open - Open PCI bus circuit - Radio Pause/Play Switch Inoperative Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6711 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6712 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6713 - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Compass/Temperature Mirror Does Calibrate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6714 Test 1 Test 2 SYMPTOM COMPASS/TEMPERATURE MIRROR DOES CALIBRATE POSSIBLE CAUSES - Calibration procedure - Compass/temperature mirror Compass/Temperature Mirror Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6715 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6716 Test 4 - 6 SYMPTOM COMPASS/TEMPERATURE MIRROR INOPERATIVE POSSIBLE CAUSES - No response - PCI bus - compass - Fused B(+) circuit short to ground - Fused B(+) circuit open - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Ground circuit open - Compass/temperature mirror High Beam Headlamps Will Not Turn Off Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6717 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Dimmer switch high beam output circuit short to voltage - Instrument cluster - Multifunction switch High Beam Headlamps Will Not Turn On Test 1 - 4 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6718 Test 5 - 7 SYMPTOM HIGH BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Open fused B+ - Dimmer switch low beam output circuit short to ground - Dimmer switch high beam output circuit short to ground - Open fuse - Dimmer switch low beam output circuit open - Instrument cluster - Multifunction switch Low Beam Headlamps Will Not Turn Off Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6719 Test 1 - 3 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN OFF POSSIBLE CAUSES - Multifunction switch - Dimmer switch low beam output circuit short to voltage - Fuse block - Instrument cluster Low Beam Headlamps Will Not Turn On Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6720 Test 1 - 4 Test 5 - 6 SYMPTOM LOW BEAM HEADLAMPS WILL NOT TURN ON POSSIBLE CAUSES - Multifunction switch - Fuse block - Dimmer switch low beam output circuit open - Instrument cluster - Open fused B+ to fuse block - Fused B+ circuit short to ground - B+ circuit breaker 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6721 All Gauges Inoperative Test 1 - 4 Test 5 - 6 SYMPTOM ALL GAUGES INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6722 POSSIBLE CAUSES - No response - PCI bus - No response - PCI bus - powertrain control module - No response - PCI bus - instrument cluster - Fused ignition switch output circuit short to ground - Fused ignition switch output circuit open - Instrument cluster ground circuit open - Instrument cluster Any or All Gauge Pointer(s) On Wrong Side of Stop Test 1 SYMPTOM ANY OR ALL GAUGE POINTER(S) ON WRONG SIDE OF STOP POSSIBLE CAUSES - Instrument cluster Any PCI Bus Indicator Inoperative Test 1 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6723 POSSIBLE CAUSES - LED defective - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6724 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake warning indicator circuit short to ground - Red brake warning indicator driver circuit short to ground - Park brake switch - Brake fluid level switch - Instrument cluster - Powertrain control module Brake Warning Indicator Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6725 Test 4 - 7 Test 8 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6726 POSSIBLE CAUSES - Brake warning indicator circuit open - Indicator led - Brake fluid level switch - Park brake switch - Red brake warning indicator driver circuit open - Brake fluid level switch ground circuit open - Instrument cluster - Powertrain control module Front Fog Lamp Indicator Inoperative Test 1 - 2 SYMPTOM FRONT FOG LAMP INDICATOR INOPERATIVE POSSIBLE CAUSES - Front fog lamp indicator circuit open - Indicator led - Instrument cluster Fuel Gauge Inaccurate Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6727 Test 1 - 2 Test 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Fuel level sensor - Intermittent condition - Instrument cluster High Beam Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6728 Test 1 - 2 SYMPTOM HIGH BEAM INDICATOR INOPERATIVE POSSIBLE CAUSES - High beam indicator circuit open - High beam indicator bulb - Instrument cluster Instrument Cluster Dimming Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6729 Test 1 - 3 SYMPTOM INSTRUMENT CLUSTER DIMMING INOPERATIVE POSSIBLE CAUSES - DTC present - Headlamp switch output circuit open - Illumination bulb - Instrument cluster Low Oil Pressure Indicator Always on Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6730 Test 1 - 3 SYMPTOM LOW OIL PRESSURE INDICATOR ALWAYS ON POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit short to ground - Powertrain control module - Instrument cluster Low Oil Pressure Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6731 Test 1 - 3 Test 4 SYMPTOM LOW OIL PRESSURE INDICATOR INOPERATIVE POSSIBLE CAUSES - Engine oil pressure switch - Engine oil pressure switch sense circuit open - Indicator led - Powertrain control module - Instrument cluster One Gauge Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6732 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE POSSIBLE CAUSES - Powertrain control module DTCs - Instrument cluster PRND or Autostick Indicator Display Inaccurate or Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6733 Test 1 - 2 SYMPTOM PRND OR AUTOSTICK INDICATOR DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - DTC present - Intermittent condition - Instrument cluster Rear Fog Lamp Indicator Inoperative - BUX Only Test 1 - 2 SYMPTOM REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY POSSIBLE CAUSES - Rear fog lamp indicator circuit open - Indicator led - Instrument cluster Seat Belt Indicator Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6734 Test 1 - 4 Test 5 SYMPTOM SEATBELT INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator led - Seat belt indicator circuit open - Seat belt switch ground open - Seat belt switch - Instrument cluster Temperature Display Inoperative or Wrong (2.0L Only) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6735 Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INOPERATIVE OR WRONG (2.0L ONLY) POSSIBLE CAUSES - DTC present in PCM - Ambient temperat1jre sensor - Compass/temperature mirror VF Display Inoperative Test 1 SYMPTOM VF DISPLAY INOPERATIVE POSSIBLE CAUSES - Instrument cluster Courtesy Lamps Inoperative - All Lamps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6736 Test 1 - 3 SYMPTOM COURTESY LAMPS INOPERATIVE - ALL LAMPS POSSIBLE CAUSES - Fused B+ circuit open - Instrument cluster - courtesy lamp open - Courtesy lamp driver circuit open - Intermittent condition Courtesy Lamps On At All Times Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6737 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6738 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6739 Test 8 - 10 SYMPTOM COURTESY LAMPS ON AT ALL TIMES POSSIBLE CAUSES - Drivers door ajar switch - Drivers door ajar switch sense wire short to ground - Remote keyless entry module - if equipped - Instrument cluster - Instrument cluster - Panel lamps dimmer signal wire short to ground - Multifunction switch - Open door ajar switch - Remote keyless entry module - if equipped - Passenger door ajar/RKE sense wire short to ground - Instrument cluster - Courtesy lamp driver circuit short to ground - Instrument cluster Illuminated Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6740 Test 1 - 2 SYMPTOM ILLUMINATED ENTRY INOPERATIVE POSSIBLE CAUSES - Courtesy lamps operational - Intermittent condition - Illuminated entry not enabled All Door Locks Inoperative Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6741 Test 3 - 7 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6742 Test 8 - 13 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6743 Test 14 - 16 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Decklid release relay output wire short to ground - Fused B(+) circuit open - Fused B(+) wire short to ground - Ground circuit open - Door lock relay output circuit open - Driver door unlock relay output short to door lock relay output - Driver door unlock relay output wire short to ground - Door lock relay output wire short to ground - Door unlock relay output short to door lock relay output - Decklid release solenoid-shorted - Door unlock relay output wire short to ground - Defective fuse #14 - RKE module - B(+) short to ground - RKE module - relays open - RKE module - shorted All Doors Except Driver Fail to Lock and Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6744 Test 1 - 4 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO LOCK AND UNLOCK POSSIBLE CAUSES - RKE module - open door unlock relay output - Door unlock relay output wire open - Door lock relay output wire open - Open motors All Doors Except Driver Fail to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6745 Test 1 SYMPTOM ALL DOORS EXCEPT DRIVER FAIL TO UNLOCK POSSIBLE CAUSES - Door unlock relay output circuit short to ground - Remote keyless entry module unlock relay Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTOMATIC DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Auto door locks not enabled - Door ajar status - PCM DTC's present - RKE module defective - auto locks inoperable Decklid Solenoid Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6746 Test 1 - 4 SYMPTOM DECKLID SOLENOID INOPERATIVE POSSIBLE CAUSES - Solenoid ground open - Decklid release solenoid open - Decklid release relay output wire open - RKE module - decklid relay open Doors Lockable With Key In Ignition and Driver Door Open Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6747 Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6748 Test 4 - 10 SYMPTOM DOORS LOCKABLE WITH KEY IN IGNITION & DRIVER DOOR OPEN POSSIBLE CAUSES - Driver door ajar switch - open - Open driver door ajar switch sense to RKE module - Ignition switch open - Key-in ignition switch sense wire open - Open driver door ajar switch sense to cluster - Instrument cluster - key-in ignition open - Instrument cluster defective-driver door ajar open - RKE module defective-open driver door ajar Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6749 Driver Door Fails to Lock and Unlock Test 1 - 3 Test 4 SYMPTOM DRIVER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - RKE module - open driver unlock circuit - Driver door lock motor - open - Driver door lock relay output wire open - Driver door unlock relay output wire open Driver Door Fails to Unlock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6750 Test 1 SYMPTOM DRIVER DOOR FAILS TO UNLOCK POSSIBLE CAUSES - Driver door unlock relay output wire short to ground - RKE module defective - driver unlock open One Passenger Door Fails to Lock and Unlock Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6751 Test 4 - 6 SYMPTOM ONE PASSENGER DOOR FAILS TO LOCK & UNLOCK POSSIBLE CAUSES - Door lock motor open - Door unlock relay output wire open - Door lock relay output wire open - Door unlock relay output wire short to ground - Door unlock relay output short to door lock relay output - Door lock relay output wire short to ground Remote Keyless Entry Inoperative Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6752 Test 1 - 3 Test 4 - 5 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - Test RKE transmitter Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6753 - RKE transmitter - inoperative - RKE module - RKE module - receiver inoperable Alarm Trips On Its Own Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition All Doors Fail to Lock Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6754 Test 1 - 4 Test 5 SYMPTOM ALL DOORS FAIL TO LOCK POSSIBLE CAUSES - Door lock relay output circuit short to ground - Decklid release relay output short to door lock relay output - Decklid release relay output short to driver door unlock relay output - Decklid release relay output short to door unlock relay output - Remote keyless entry module - unlock ground open All Locks Inoperative From A Door Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6755 Test 1 - 3 Test 4 - 6 SYMPTOM ALL LOCKS INOPERATIVE FROM A DOOR LOCK SWITCH POSSIBLE CAUSES - DTC present Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6756 - Door switch ground wire open - Door switch MUX wire short to voltage - Door switch MUX wire open - Door lock switch open - Remote keyless entry module - high voltage - Remote keyless entry module - low voltage Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH DURING ALARM POSSIBLE CAUSES - Dimmer switch low beam output circuit open - Remote keyless entry module Horn Fails to Sound When Alarm Is Tripped Test 1 SYMPTOM HORN FAILS TO SOUND DURING ALARM POSSIBLE CAUSES - Horn relay control circuit open - Remote keyless entry module Intrusion Sensor Cannot Be Disabled Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6757 Test 1 SYMPTOM INTRUSION SENSOR CANNOT BE DISABLED (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Intrusion Sensor Fails to Trip VTSS Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6758 Test 4 - 6 SYMPTOM INTRUSION SENSOR FAILS TO TRIP VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Open fused B(+) circuit - Open ground circuit - Intrusion sensor signal circuit open - Intrusion sensor signal circuit shorted to ground - Intrusion sensor - Remote keyless entry module Intrusion Sensor Repeatedly Triggers VTSS Test 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6759 SYMPTOM INTRUSION SENSOR REPEATEDLY TRIGGERS VTSS (EXPORT ONLY) POSSIBLE CAUSES - Intrusion sensor - Remote keyless entry module Open Driver Door Fails to Trip Alarm Test 1 - 3 SYMPTOM OPEN DRIVER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Remote keyless entry module Open Passenger Door Fails to Trip Alarm Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6760 Test 1 - 2 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6761 Test 3 - 6 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6762 Test 7 - 8 SYMPTOM OPEN PASSENGER DOOR FAILS TO TRIP ALARM POSSIBLE CAUSES - Left rear door ajar switch ground circuit open - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Right rear door ajar switch ground circuit open - Passenger door ajar/RKE sense circuit open - Left rear door ajar switch - Passenger door ajar/RKE sense circuit open - Right rear door ajar switch - Passenger door ajar/RKE circuit open - Passenger door ajar/RKE sense circuit open - Remote keyless entry module - RKE module - passenger door ajar sense Park Lamps Fail to Flash During Alarm Test 1 SYMPTOM PARK LAMPS FAIL TO FLASH DURING ALARM Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6763 POSSIBLE CAUSES - Park lamp switch output circuit open - Remote keyless entry module VTSS Fails to Arm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Fails to Arm From Passenger Door Cylinder Lock Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6764 Test 1 - 3 SYMPTOM VTSS FAILS TO ARM FROM PASSENGER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY) POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Passenger door switch MUX circuit open - Passenger cylinder lock switch faulty VTSS Fails to Arm/Disarm From Driver Door Cylinder Lock Switch Test 1 - 3 SYMPTOM VTSS FAILS TO ARM/DISARM FROM DRIVER DOOR CYLINDER LOCK SWITCH Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6765 TEST NOTE This symptom is diagnosed using the test VTSS FAILS TO ARM FROM DRIVER DOOR CYLINDER LOCK SWITCH (EXPORT ONLY). POSSIBLE CAUSES - Door lock operation test - Ground circuit open - Driver door switch MUX circuit open - Driver cylinder lock switch faulty VTSS Indicator Fails to Flash Test 1 - 3 SYMPTOM VTSS INDICATOR FAILS TO FLASH POSSIBLE CAUSES - Remote keyless entry module - Instrument cluster - VTSS indicator driver circuit open - VTSS led open VTSS Indicator Stays On Steady During Arming Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6766 Test 1 - 5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6767 Test 6 - 8 SYMPTOM VTSS INDICATOR STAYS ON STEADY DURING ARMING POSSIBLE CAUSES - Decklid security switch sense circuit open (if equipped) - Decklid security switch ground circuit open (if equipped) - Decklid security switch (if equipped) - Hood ajar switch sense circuit shorted to ground (if equipped) - Hood ajar switch (if equipped) - RKE module - VTSS indicator - RKE module - hood ajar (if equipped) - RKE module - decklid security (if equipped) VTSS Siren Inoperative Test 1 - 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6768 Test 4 - 6 SYMPTOM VTSS SIREN INOPERATIVE (EXPORT ONLY) POSSIBLE CAUSES - Siren functional test - Open fused B(+) circuit - Open ground circuit - Faulty siren - Siren control circuit open - Siren control circuit shorted to ground - Remote keyless entry module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6769 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Road Testing ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. during the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Airbag System AIRBAG SYSTEM The Airbag Control Module (ACM) is bolted to the floor panel transmission tunnel rearward from the gear shift selector inside the vehicle. The ACM mounting bracket is welded to the tunnel and is not serviced with the ACM. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry via the PCI data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the PCI data bus to turn on the airbag indicator lamp. A preprogrammed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe "symptoms" of system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the airbag warning lamp on for 6-8 seconds. If the lamp turns off; it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off; there is usually an intermittent problem in the system. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6770 DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the malfunction is currently there every time the control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. An "Interrogate Right SIACM or Interrogate left SIACM" diagnostic trouble code indicates an active trouble code in the respective module. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute, Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter Will be reset and the diagnostic trouble code Will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. WARNING: MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING INSPECTION: If no obvious problems are found: Erase the stored codes - Place the ignition in the Run position - Wiggle the wire harness and connectors - Rotate the steering wheel from stop to stop - Recheck for active codes periodically as you work through the system. Electro/Mechanical Instrument Cluster (EMIC) ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) There are 4 (four) different types of Instrument Clusters. Base, Premium, Luxury, and AutoStick. The Premium cluster is equipped with a tachometer and a low fuel indicator. The Luxury has the same features as the Premium with an additional black overlay and chrome rings. The AutoStick is the Luxury cluster with the AutoStick function. The Transmission controller (TCM) controls the vacuum fluorescent (VF) PRND or AutoStick display. The cluster will illuminate the appropriate PRND or gear position based on PCI Bus data received from the TCM. The Instrument Cluster Speedometer; Tachometer; and Engine Coolant Temperature gauges are positioned using PCI Bus messages received from the PCM. The Fuel gauge is a hard wired input from the Fuel Level Sensor in the Fuel Pump Module. The Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent (VF) display that is controlled by PCI Bus messages received from the PCM. The VF display also displays the "Door", "Cruise", and "Trac" messages. If the Instrument Cluster experiences a loss of PCI Bus communication with other modules on the Bus, the Cluster will display "nobus" in the VF display. The illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned on, the Cluster receives a hard wire input from the Multi-Function Switch. The Cluster sends a Panel Lamps Dimmer Signal to ground through the Multi-Function Switch. The varying voltage drop is sensed by the Instrument Panel Drivers to create a corresponding amount of illumination dimming. This dimming level is then sent out from the Cluster to other components. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6771 The Cluster will communicate with the DRB III(R) to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the off to the on position. The Cluster will position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The Cluster will also illuminate each segment of the VF display. If the Cluster does not detect voltage on the Courtesy Lamp circuit, the message "FUSE" will alternate with the odometer/trip odometer for 30 (thirty) seconds after the ignition is turned on and for 15 (fifteen) seconds after the vehicle is first moved. Glossary of Terms ABS Antilock Brake System ACM Airbag Control Module AECM Airbag Electronic Control Module (ACM) ASDM Airbag System Diagnostic Module (ACM) BUX Built-Up Export CAB Controller Antilock Brake CTM Compass/Temperature Mirror DAB Driver Airbag DLC Data Link Connector DTC Diagnostic Trouble Code EMIC Electro/Mechanical Instrument Cluster LSIACM Left SIACM NGC Next Generation Controller PAB Passenger Airbag PCI Programmable Communication Interface (Vehicle Communication Bus) PCM Powertrain Control Module PDC Power Distribution Center PWM Pulse Width Modulated RKE Remote Keyless Entry RSIACM Right SIACM SAB Side Airbag SIACM Side Impact Airbag Control Module SKIM Sentry Key Immobilizer Module SKIS Sentry Key Immobilizer System SQUIB Also Called Initiator (Located In Rear Of Airbag Module) TCM Transmission Control Module VFD Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6772 Body Control Module: Scan Tool Testing and Procedures DRB III Error Messages and Blank Screen DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6773 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. DRB III Safety Information DRB III (R) SAFETY INFORMATION WARNING: EXCEEDING THE LIMITS OF THE DRB III (R) MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLE FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS. Follow the vehicle manufacture's service specifications at all times. Do not use the DRB Ill(R) if it has been damaged. Do not use the test leads if the insulation is damaged or if metal is exposed. To avoid electrical shock, do not touch the test leads, tips, or other circuit being tested. Choose the proper range and function for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Do not exceed the limits shown in the table. Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. The circuit being tested must be protected by a 10A fuse or circuit breaker. Use the low current shunt to measure circuits up to 10A. Use the higher current clamp to measure circuits exceeding 10A. When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. When measuring current, connect the meter in series with the load. Disconnect the live test lead before disconnecting the common test lead. When using the meter function, keep the DRB III (R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6774 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (R) (diagnostic read out box) Jumper Wires Ohmmeter Voltmeter Test Light 8310 Airbag Load Tool 8443 SRS Airbag System Load Tool Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL 1. Remove splash shield attaching screws. Fig. 1 2. Remove fasteners attaching air dam to cross-member (Fig. 1). Fig. 2 3. SRT-4 vehicle remove four attaching screws (Fig. 2). 4. Disconnect fog lamp wiring harness, if equipped. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 6780 Fig. 3 Fig. 4 5. Remove nuts attaching front bumper fascia to bottom of fender flange. (Fig. 3), and (Fig. 4). 6. Remove fascia from vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 6781 Fig. 5 7. SRT-4 vehicle remove the fascia to crossmember upper blockers from the fascia (Fig. 5). INSTALLATION 1. SRT-4 vehicle place into position the fascia to crossmember upper blockers to the fascia (Fig. 5). 2. Position fascia on vehicle , (Fig. 3) and (Fig. 4). 3. Install nuts attaching front bumper fascia to bottom of fender flange. 4. Attach fascia horns to radiator crossmember. 5. SRT-4 vehicle install air dam four attaching screws (Fig. 2). 6. Install air dam to crossmember fasteners (Fig. 1). 7. Install splash shield attaching screws. 8. Connect fog lamp wiring harness. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER REINFORCEMENT REMOVAL 1. Remove front bumper fascia. Refer to Front Bumper. 2. Support bumper reinforcement on a suitable lifting device. Fig. 6 3. Remove nuts attaching reinforcement to the rail assembly (Fig. 6). 4. Remove bumper reinforcement from vehicle. 5. Remove bolt attaching energy absorbers to beam, and peal energy absorbers from beam, if equipped. INSTALLATION 1. Install energy absorbers to beam and install attaching bolt. 2. Place bumper reinforcement in position (Fig. 6). 3. Support bumper reinforcement on a suitable lifting device. 4. Install nuts attaching reinforcement to rail assembly. 5. Install front fascia. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR FASCIA REMOVAL 1. Release decklid lock and open decklid. Fig. 7 2. Remove screws and screw pin fasteners attaching fascia in the trunk (Fig. 7). 3. Raise vehicle on hoist. 4. Disconnect license lamp. 5. Remove splash shield from fascia in the wheel opening area. 6. From under license plate area, remove fasteners attaching lower fascia. 7. Remove nuts attaching fascia to lower quarter panels. 8. Remove fascia from vehicle. INSTALLATION 1. Position fascia on vehicle. 2. Install nuts attaching fascia to lower quarter panels (Fig. 7). 3. From under license plate area, install fasteners attaching lower fascia. 4. Install splash shield in the wheel opening area. 5. Connect license lamp. 6. Lower vehicle. 7. Install screws and screw pin fasteners attaching fascia in the trunk. 8. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER REINFORCEMENT REMOVAL Fig. 8 1. Remove rear fascia (Fig. 8). 2. Support bumper reinforcement on a suitable lifting device. 3. Remove screws attaching reinforcement to rear closure panel. 4. Remove bumper reinforcement from vehicle. INSTALLATION 1. Position bumper reinforcement to vehicle. 2. Install screws attaching reinforcement to rear closure panel. 3. Install rear fascia. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE SCREEN REMOVAL 1. Release hood latch and open hood. 2. Remove windshield wiper arms. Fig. 1 3. Remove the five screws attaching cowl screen cover to just below windshield flange. (Fig. 1). 4. Remove cowl plenum to hood weatherstrip, at the leading edge of cowl cover. Pull weatherstrip towards the front of the vehicle to remove. 5. Remove cowl screen windshield seal from upper edge of the cowl screen cover. 6. Remove cowl screen cover from the vehicle. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 6796 Fig. 2 1. Place cowl screen cover into position on vehicle (Fig. 2). 2. Start five screws attaching cowl screen cover to cowl at base of windshield opening. 3. Install cowl screen windshield seal to upper edge of the cowl screen. 4. Push cowl plenum to hood weatherstrip, into position on the leading edge of cowl screen cover. 5. Install windshield wiper arms. 6. Tighten screws attaching cowl screen cover to cowl at base of windshield opening. 7. Install windshield wiper arms. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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. 2. Remove the waterdam as necessary to gain access to the exterior handle and door latch mechanisms. 3. Close door glass. 4. Disconnect lock and latch rods from door latch. Fig. 7 5. Remove screws attaching door handle retainer to outer door panel (Fig. 7). 6. Remove door handle from vehicle. INSTALLATION 1. Position door handle into door and install retainer at back of handle. 2. Install the screws attaching door handle retainer to outer door panel. 3. Connect lock and latch rods to door latch. 4. Place waterdam onto the door and pressurize at the butyl bead to seal completely. 5. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair FRONT DOOR HINGE REMOVAL 1. Open and support door on a suitable lifting device. 2. Remove bolts attaching door check strap to lower A-pillar for greater access, if necessary. 3. Mark position of hinge on both the door end frame and lower A-pillar to ease installation. Fig. 4 4. Remove bolts attaching hinge to door end frame (Fig. 4). 5. Remove bolts attaching hinge to lower A-pillar. 6. Remove door hinge from vehicle. INSTALLATION CAUTION: When installing a new hinge, make sure that the head of each hinge pin is fully seated into the door hinge. Also, remove the plastic shipping clip and replace it with the correct metal retaining clip once the hinge pin is seated. 1. If necessary, paint new door hinge prior to installation. 2. Position door hinge on vehicle. 3. Loosely install bolts attaching hinge to lower A-pillar. 4. Loosely install bolts attaching hinge to door end frame. 5. Align hinge to marks made previously and tighten all bolts. 6. Install bolts attaching door check strap to lower A-pillar, if removed previously. 7. Verify door fit and operation. Adjust door hinge for proper door alignment, if necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENTS 1. Insert a hex-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen socket head screw on the side of the latch linkage. 3. Lift upward on outside door handle and release it. 4. Tighten socket head screw on latch. 5. Verify latch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6810 Front Door Latch: Service and Repair LATCH REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. Fig. 8 3. Disconnect lock and latch rods from door latch (Fig. 8). 4. Disengage wire connector from power door lock motor, if equipped. 5. Remove screws holding latch to door end frame. 6. Remove door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to open. 1. Position door latch inside door and install screws holding latch to door end frame. 2. Engage wire connector into power door lock motor, if so equipped. 3. Connect latch and lock rods to door latch. 4. Install door trim panel and water shield. 5. Adjust door latch using procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair CHECK STRAP REMOVAL 1. Remove door trim panel and water dam. 2. Remove bolt attaching check strap to hinge pillar. 3. Remove door speaker. 4. Remove glass run. Fig. 3 5. Remove bolts attaching check strap to door end frame (Fig. 3). 6. Remove check strap from vehicle. INSTALLATION NOTE: Do not grease check strap. 1. Position door check on vehicle and install bolts attaching strap to door end frame. 2. Install glass run. 3. Install door speaker, if so equipped. 4. Install bolt attaching door check strap to hinge pillar. 5. Install door trim panel and water dam. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Trim Panel Front Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Lower door glass. Fig. 13 3. Remove window regulator crank, if so equipped (Fig. 13). Fig. 11 4. Remove screw from inside arm rest pull cup (Fig. 11). 5. Remove screw from behind inside latch release handle. 6. Disengage push-in fasteners attaching trim to door panel around perimeter of trim panel. 7. Tilt trim panel outward to clear locator pins on backside of trim panel. 8. Disconnect trim panel from retainer channel in inner belt weatherstrip at top of door by lifting while gently jiggling. 9. Move trim panel away from door and disengage clip attaching latch rod to handle. 10. Remove latch rod from handle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Trim Panel > Page 6818 CAUTION: Do not allow door trim panel to hang by the wire connector or wiring. 11. Disconnect wire connector from power door lock switch, mirror switch, and power window switch if so equipped. 12. Remove trim panel from door. INSTALLATION 1. Replace any damaged or missing push in fasteners from around perimeter of door trim panel. 2. Place trim panel near door. 3. Connect wire connector into power door lock switch, mirror switch, and power window switch , if so equipped. 4. Insert latch rod into handle and engage clip. 5. Install trim panel into retainer channel at top of door and push down to seat. 6. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 7. Install push in fasteners to hold trim to door panel around perimeter of trim panel. 8. Install screw inside latch release handle. 9. Install screw inside arm rest pull cup. 10. With the window in the down position, 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 so equipped. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Trim Panel > Page 6819 Front Door Panel: Service and Repair Waterdam WATERDAM REMOVAL 1. Remove door trim panel. 2. Remove door speaker, if equipped. 3. Remove door trim pull cup mount bracket. 4. Disconnect clip attaching lock linkage to lock button bell-crank. Fig. 12 5. Peel water dam away from adhesive around perimeter of inner door panel (Fig. 12). INSTALLATION 1. Insure that enough adhesive remains to securely retain the water dam. Replace as necessary. 2. Place the water dam into position and press securely to adhesive making sure to properly route wiring and linkages. 3. Engage clip attaching lock linkage to lock button bell-crank. 4. Install door trim pull cup mount bracket. 5. Install door speaker, if equipped. 6. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Mark outline of door latch striker on B-pillar to aid installation. Fig. 9 2. Remove screws attaching door latch striker to B-pillar (Fig. 9). 3. Remove door latch striker from vehicle. INSTALLATION 1. Install door latch striker into the door. 2. Install screws attaching door latch striker to B-pillar loosely. 3. Align door latch striker to outline marks on the B-pillar 4. Tighten screws attaching door latch striker to B-pillar. 5. Check door alignment and adjust as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar Front Door Window Glass Weatherstrip: Service and Repair Front Vertical Guide Bar FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6828 Front Door Window Glass Weatherstrip: Service and Repair B-Pillar Weatherstrip Channel B-PILLAR WEATHERSTRIP CHANNEL REMOVAL 1. Remove b-pillar applique. 2. Remove push in fasteners attaching weatherstrip to b-pillar. 3. Pull weatherstrip from b-pillar channels. 4. Remove screws attaching channels to b-pillar. 5. Remove channels from b-pillar. INSTALLATION 1. Install channels from b-pillar. 2. Install screws attaching channels to b-pillar. 3. Install weatherstrip to b-pillar channels. 4. Install push in fasteners attaching weatherstrip to b-pillar. 5. Install b-pillar applique. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6829 Front Door Window Glass Weatherstrip: Service and Repair FDR Glass Run Weatherstrip FDR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove flag cover, door trim panel, water dam as necessary. 2. Remove door glass. 3. Loosen side view mirror, as necessary. 4. Remove weatherstrip fasteners. 5. Pull weatherstrip from lower front channel above door latch. Fig. 1 6. Pull run weatherstrip from window frame channel (Fig. 1). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Tighten side view mirror. 8. Install pull cup support bracket, water shield, door trim panel and flag trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6830 Front Door Window Glass Weatherstrip: Service and Repair Outer Belt Weatherstrip OUTER BELT WEATHERSTRIP REMOVAL 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Fig. 2 3. Remove outer belt weatherstrip from vehicle (Fig. 2). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6831 Front Door Window Glass Weatherstrip: Service and Repair Front Vertical Guide Bar FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. B-Pillar Weatherstrip Channel B-PILLAR WEATHERSTRIP CHANNEL REMOVAL 1. Remove b-pillar applique. 2. Remove push in fasteners attaching weatherstrip to b-pillar. 3. Pull weatherstrip from b-pillar channels. 4. Remove screws attaching channels to b-pillar. 5. Remove channels from b-pillar. INSTALLATION 1. Install channels from b-pillar. 2. Install screws attaching channels to b-pillar. 3. Install weatherstrip to b-pillar channels. 4. Install push in fasteners attaching weatherstrip to b-pillar. 5. Install b-pillar applique. FDR Glass Run Weatherstrip FDR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove flag cover, door trim panel, water dam as necessary. 2. Remove door glass. 3. Loosen side view mirror, as necessary. 4. Remove weatherstrip fasteners. 5. Pull weatherstrip from lower front channel above door latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6832 Fig. 1 6. Pull run weatherstrip from window frame channel (Fig. 1). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Tighten side view mirror. 8. Install pull cup support bracket, water shield, door trim panel and flag trim. Outer Belt Weatherstrip OUTER BELT WEATHERSTRIP REMOVAL 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6833 Fig. 2 3. Remove outer belt weatherstrip from vehicle (Fig. 2). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Door Upper Secondary Weatherstrip DOOR UPPER SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 6834 Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Move the window to the full-up position, if possible. 3. Remove front door trim panel. 4. Remove front door water shield. 5. Remove three screws to front door radio speaker so that motor has room to pivot. 6. Pivot window motor out of door panel. 7. Remove three motor retaining screws to drive cable. 8. Remove motor from drive cable assembly. INSTALLATION 1. Install motor to the cable drive assembly. 2. Install motor retaining screws to drive cable. 3. Install the screws to the front door radio speaker. 4. Install the front door water shield. 5. Install the front door trim panel. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > 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. 5 4. Remove nuts attaching outside handle to door (Fig. 5). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair HINGE REMOVAL NOTE: If both hinges on one door are to be replaced, remove and install one hinge completely prior to beginning the second hinge. 1. Open and support door on a suitable lifting device. 2. Remove bolts attaching door check strap to lower B-pillar for greater access, if necessary. 3. Mark position of hinge on both the door end frame and lower B-pillar to ease installation. Fig. 3 4. Remove bolts attaching hinge to door end frame (Fig. 3). 5. Remove bolts attaching hinge to lower B-pillar. 6. Remove door hinge from vehicle. INSTALLATION NOTE: - If both hinges on one door are to be replaced, remove and install one hinge completely prior to beginning the second hinge. - Do not grease door hinges. 1. If necessary, paint new door hinge prior to installation. 2. Position door hinge on vehicle. 3. Loosely install bolts attaching hinge to lower B-pillar. 4. Loosely install bolts attaching hinge to door end frame. 5. Align hinge to marks made previously and tighten all bolts. 6. Install bolts attaching door check strap to lower B-pillar, if removed previously. 7. Verify door fit and operation. Adjust door hinge for proper door alignment, if necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments ADJUSTMENTS 1. Insert a hex-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen socket head screw on the side of the latch linkage. 3. Lift upward on outside door handle and release it. 4. Tighten socket head screw on latch. 5. Verify latch operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments > Page 6849 Rear Door Latch: Service and Repair LATCH REMOVAL 1. Remove door trim panel. 2. Close door glass. 3. Loosen lower rear run channel. 4. Disconnect clips attaching linkage rods to door latch. Fig. 6 5. Remove linkage rods from latch (Fig. 6). 6. Remove screws attaching latch to door end frame. 7. Remove door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to open. 1. Position door latch on vehicle and install screws attaching latch to door end frame. 2. Connect linkage rods to latch. 3. Connect lock and latch rods to door latch. 4. Tighten lower rear run channel. 5. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair Rear Door Limiter: Service and Repair CHECK STRAP REMOVAL 1. Remove door trim panel. 2. Remove bolts attaching check strap to hinge pillar. 3. Remove check strap seal from door end frame. Fig. 2 4. Remove bolts attaching check strap to door end frame (Fig. 2). 5. Remove check strap from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to open. 1. Position door check strap on vehicle. 2. Install check strap attaching bolts to the door end frame. 3. Install check strap seal. If seal is damaged or worn replace seal. 4. Install check strap attaching bolts to the hinge pillar. 5. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel Rear Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Lower window glass. 3. Remove window regulator crank. 4. Remove screw from inside arm rest pull cup. Fig. 7 5. Remove screw from behind inside latch release handle (Fig. 7). 6. Disengage push in fasteners attaching trim to door panel around perimeter of trim panel. 7. Disengage push-in metal spring clip holding trim in sail flag area. 8. Lift trim panel up off belt weatherstrip. 9. Tilt top of trim panel away from door and disengage clip attaching latch rod to handle. 10. Remove latch rod from handle. 11. Remove trim panel from door. INSTALLATION 1. Replace any damaged or missing push in fasteners from around perimeter of door trim panel. 2. Place trim panel in position on door. 3. Insert latch rod into handle and engage clip. 4. Engage trim panel into retainer channel at top of door. 5. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 6. Engage push in fasteners attaching trim to door panel around perimeter of trim panel. 7. Install screw behind inside latch release handle. 8. Install screw inside arm rest pull cup. 9. Install window regulator crank. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 6857 Rear Door Panel: Service and Repair Waterdam WATERDAM REMOVAL 1. Remove door trim panel. 2. Remove door speaker, if equipped. 3. Remove door trim pull cup mount bracket. 4. Disconnect clip attaching lock linkage to lock button bell-crank. Fig. 8 5. Peel water dam away from adhesive around perimeter of inner door panel (Fig. 8). INSTALLATION 1. Insure that enough adhesive remains to securely retain the water dam. Replace as necessary. 2. Place the water dam into position and press securely to adhesive making sure to properly route wiring and linkages. 3. Engage clip attaching lock linkage to lock button bell-crank. 4. Install door trim pull cup mount bracket. 5. Install door speaker, if equipped. 6. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Mark outline of door latch striker on B-pillar to aid installation. Fig. 4 2. Remove screws attaching door latch striker to B-pillar (Fig. 4). 3. Remove door latch striker from vehicle. INSTALLATION 1. Install door latch striker from vehicle. 2. Install screws attaching door latch striker to B-pillar. 3. Align marked outline of door latch striker on B-pillar to aid installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6866 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door trim panel, water dam as necessary. 2. Remove door glass. 3. Remove weatherstrip fasteners. 4. Pull weatherstrip from lower front channel above door latch. Fig. 4 5. Pull run weatherstrip from window frame channel (Fig. 4). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Install pull cup support bracket, water shield, and door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6867 Rear Door Window Glass Weatherstrip: Service and Repair RDR Secondary Weatherstrip RDR SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool C-4829 or equivalent, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6868 Rear Door Window Glass Weatherstrip: Service and Repair Roof Rail Weatherstrip ROOF RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. 2. Using a door trim removing tool, disengage the push-in fasteners holding A-pillar and C-pillar weatherstrip molding. 3. Starting at the bottom of the A-pillar, pull the roof rail weatherstrip from the windshield side molding. Fig. 5 4. Pull roof rail weatherstrip from the roof rail pinch flange above the door opening (Fig. 5). 5. Separate roof rail weatherstrip from vehicle. INSTALLATION 1. Place weatherstrip in position on pinch flange. 2. Starting at the bottom of the C-pillar, install the roof rail weatherstrip molding to the pinch rail. 3. Install push-in fasteners to hold weatherstrip to A-pillar and C-pillar. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6869 Rear Door Window Glass Weatherstrip: Service and Repair Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door trim panel, water dam as necessary. 2. Remove door glass. 3. Remove weatherstrip fasteners. 4. Pull weatherstrip from lower front channel above door latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6870 Fig. 4 5. Pull run weatherstrip from window frame channel (Fig. 4). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Install pull cup support bracket, water shield, and door trim panel. RDR Secondary Weatherstrip RDR SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool C-4829 or equivalent, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Roof Rail Weatherstrip ROOF RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. 2. Using a door trim removing tool, disengage the push-in fasteners holding A-pillar and C-pillar weatherstrip molding. 3. Starting at the bottom of the A-pillar, pull the roof rail weatherstrip from the windshield side molding. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6871 Fig. 5 4. Pull roof rail weatherstrip from the roof rail pinch flange above the door opening (Fig. 5). 5. Separate roof rail weatherstrip from vehicle. INSTALLATION 1. Place weatherstrip in position on pinch flange. 2. Starting at the bottom of the C-pillar, install the roof rail weatherstrip molding to the pinch rail. 3. Install push-in fasteners to hold weatherstrip to A-pillar and C-pillar. Roof Rail Weatherstrip Retainer Channel ROOF RAIL WEATHERSTRIP RETAINER CHANNEL REMOVAL 1. Open door(s). 2. Using trim stick disconnect 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, ensure all of the old two sided tape is removed from the vehicle surface before installation of new part. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6872 Fig. 6 3. Remove weatherstrip from the retainer channel (Fig. 6). 4. Remove retainer channel from the body side aperture. INSTALLATION 1. Install retainer channel to the body side aperture. 2. Remove weatherstrip from the retainer channel. 3. Connect the top and bottom push in fasteners to B-pillar applique. Gently push on the applique to install from the vehicle. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL Fig. 7 1. Using a fork-type prying tool, disengage push in fasteners attaching sill secondary weatherstrip to door (Fig. 7). 2. Remove weatherstrip from door. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 6873 INSTALLATION 1. Position weatherstrip to door. 2. Press sill secondary weatherstrip fasteners into position. Trunk Opening Weatherstrip TRUNK OPENING WEATHERSTRIP REMOVAL 1. Open decklid. Fig. 8 2. Pull decklid weatherstrip form decklid opening fence (Fig. 8). 3. Remove weatherstrip from vehicle. INSTALLATION 1. Place decklid opening weatherstrip into position. 2. Press the weatherstrip onto the decklid opening fence. 3. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove door glass from regulator channel. Tie Strap Door Regulator Cable 3. Cut away the tie strap from the outboard regulator cable. Rear Door Glass 4. Loosen screws attaching window regulator channel and crank housing to door panel. 5. Disengage screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching window regulator to door panel. 7. Disengage regulator from door panel, and crank housing. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel, Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 6877 9. Remove window regulator from door through access hole in inner panel. INSTALLATION 1. Position window regulator and crank housing on door panel through access hole in door panel. 2. Tighten bolts attaching window regulator to door panel. 3. Engage window regulator bolt heads on channel to key hole slots in door panel. 4. Tighten screw attaching window regulator channel and crank housing. 5. Install a new tie strap around the outboard regulator cable and door inner sheet metal. 6. Position glass to regulator roller channel. 7. Tighten fasteners attaching door glass to roller channel. 8. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair REMOVAL 1. Open the fuel filler door. Fig. 5 2. Remove the screws attaching the door to the quarter panel (Fig. 5). 3. Remove the door from the panel. INSTALLATION 1. Position the fuel filler door on the quarter panel with the screw holes aligned. 2. Install the screws attaching the fuel filler door to the quarter panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE REMOVAL 1. Support hood on the side that requires hinge replacement. 2. Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. When installing hood hinge, align all marks and secure bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. Fig. 1 3. Remove bolts holding hood to hinge (Fig. 1). 4. Remove bolts holding hood hinge to load beam flange and separate hinge from vehicle. If necessary, paint new hinge before installation. INSTALLATION 1. If necessary, paint new hinge before installation. 2. Place hinge in position on vehicle. 3. Install bolts to hold hood hinge to front fender flange. 4. Install bolts to hold hood to hinge. 5. Align all marks and secure bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. 6. Remove support from under hood and verify hood operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair SILENCER PAD REMOVAL 1. Release hood latch and open hood. Fig. 8 2. Disconnect hood lamp wire connector and remove hood lamp (Fig. 8). 3. Remove fasteners attaching hood silencer to hood. 4. Remove hood silencer from vehicle. INSTALLATION 1. Place hood silencer in position on vehicle. 2. Install fastener attaching hood silencer to hood. 3. Install hood lamp and connect wire connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair LATCH REMOVAL Domestic Fig. 4 1. Remove the upper fasteners securing the grille to the upper radiator closure panel. (Fig. 4) Fig. 5 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 6891 2. Using a socket and extension, remove the nuts attaching hood latch to radiator closure panel. (Fig. 5) 3. Carefully pull the grille out from the radiator closure and remove the hood latch assembly. 4. Disengage remote release cable from latch. International 1. Release hood latch and open hood. 2. Support hood on prop rod. 3. Remove grille. 4. Remove nuts attaching hood latch to radiator closure panel (Fig. 5). 5. Remove hood latch from closure panel. 6. Disengage remote release cable from latch. INSTALLATION Domestic 1. Engage remote release cable into latch. 2. Carefully pull back the grille and place hood latch onto radiator closure panel. 3. Install the nuts and tighten to 15 N.m (11 ft.lbs.). 4. Install the upper fasteners securing the grille to the upper radiator closure panel. International 1. Engage remote release cable into latch. 2. Place hood latch onto radiator closure panel. 3. Install nuts attaching latch to closure panel and tighten to 15 N.m (11 ft.lbs.). 4. Install grille. 5. Close hood and verify alignment of hood and that latch is securely engaged. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE REMOVAL 1. Unlatch hood and open 2. Disconnect remote hood release cable from hood latch. Fig. 6 3. Release any remote hood cable attachments and free cable (Fig. 6). 4. Remove left front cowl trim panel, Refer to Trim Panel. Fig. 7 5. Remove screws attaching hood release handle to cowl panel and release cable from clip (Fig. 7). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 6895 6. Disconnect rubber grommet from dash panel behind instrument panel. 7. Pull release cable through hole in dash panel. 8. Remove cable and handle from vehicle. INSTALLATION 1. From inside of vehicle feed remote release cable through hole in dash panel (Fig. 7) 2. Connect rubber grommet into dash panel. 3. Install screws attaching hood release handle to cowl panel. 4. Install left front cowl trim panel. 5. Connect any remote cable attachments (Fig. 6). 6. Connect remote hood release cable to hood latch. 7. Close hood and verify operation. 8. Check remote hood release cable for proper operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair ADJUSTMENT BUMPER REMOVAL 1. Release hood latch and open hood. 2. Rotate hood adjuster bumper counterclockwise. 3. Remove hood adjuster bumper from headlamp reinforcement. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Service and Repair Hood Striker: Service and Repair LATCH STRIKER REMOVAL 1. Release hood latch and open hood. 2. Remove bolts attaching striker to inside of hood. 3. Remove hood latch striker from vehicle. INSTALLATION 1. Position hood latch striker on vehicle. 2. Install bolts attaching hood latch striker to hood. Tighten bolts to 13.5 N.m (10 ft.lbs.) torque. 3. Align hood latch striker to engage smoothly into hood latch. 4. Verify hood operation and alignment. Adjust as necessary. 5. Tighten attaching bolts to 13.5 N.m (10 ft.lbs.) torque. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6906 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH (EXPORT) REMOVAL 1. Open hood. Fig.1 Battery Negative Cable - Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Disconnect wire harness connector from hood ajar switch. Fig.2 Hood Ajar Switch Location 4. Firmly press tangs on the bottom side of the switch together and push up through bracket. 5. Remove switch from vehicle. INSTALLATION 1. Firmly press hood ajar switch through bracket. 2. Connect wire harness connector to hood ajar switch. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Cover > System Information > Service and Repair Trunk / Liftgate Cover: Service and Repair COVER REMOVAL Fig. 1 1. Remove fasteners attaching decklid cover to vehicle (Fig. 1). 2. Remove decklid cover from vehicle. INSTALLATION 1. Position cover on decklid over the striker. 2. Install push in fasteners. 3. Seat the lower edges of the carpet and smooth out. 4. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair LATCH REMOVAL 1. Open decklid. Fig. 3 2. Remove bolts attaching decklid latch to decklid (Fig. 3). 3. Remove attaching latch from decklid. 4. Disconnect remote decklid latch release cable form decklid latch. 5. Disconnect decklid ajar switch connector from latch. 6. Remove latch from vehicle. INSTALLATION 1. Place decklid latch into position (Fig. 3). 2. Connect remote decklid latch wire connector to decklid latch. 3. Connect decklid ajar and lamp switch connector to latch. 4. Install bolts attaching decklid latch to decklid lid. 5. Check decklid latch for proper alignment. 6. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Service and Repair Trunk / Liftgate Latch Release Cable: Service and Repair EMERGENCY RELEASE CABLE REMOVAL 1. Remove the decklid cover. Refer to Trim Panel. Fig. 6 2. Unclip cable and handle assembly (Fig. 6). INSTALLATION 1. Attach emergency release cable clip to the latch stud. 2. Install the decklid cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL Fig. 2 1. Remove decklid latch. 2. Remove clip attaching decklid lock cylinder to decklid. 3. Pull lock cylinder from decklid (Fig. 2). INSTALLATION 1. Place lock cylinder into position. 2. Install clip attaching decklid lock cylinder to decklid. 3. Install decklid latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Component Locations > Page 6924 Fig. 48 Decklid - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 6925 Decklid Solenoid Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 6926 Trunk / Liftgate Solenoid: Testing and Inspection DECKLID SOLENOID TEST 1. Confirm operation of RKE transmitter(s) by actuating LOCK and UNLOCK functions. 2. Confirm lead is connected to the deck lid release solenoid. 3. Unplug lead, and use an ohmmeter to verify continuity of connection between pin 2 of the harness connector and ground. 4. Connect test light to pin 1 of the harness connector and actuate deck lid release button on transmitter. 5. If test light comes ON, the wiring circuit between the RKE module and the solenoid is functional, and the deck lid solenoid should be replaced. 6. If test light does not come on, refer to the proper Body Diagnostic Procedures for further troubleshooting information. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 6927 Trunk / Liftgate Solenoid: Service and Repair DECKLID SOLENOID REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise deck lid to the full up position. 3. Unplug connector from solenoid. 4. Remove two solenoid mounting screws. 5. Remove solenoid from vehicle. INSTALLATION 1. Install the solenoid into the vehicle. 2. Install the two solenoid mounting screws. 3. Plug the connector into the solenoid. 4. Close the deck lid. 5. Connect the battery negative cable. Adjust the deck lid latch and striker so that the deck lid latches with a moderate slam and so that the deck lid releases properly whenever the power deck lid release is activated. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Spring > Component Information > Service and Repair Trunk / Liftgate Spring: Service and Repair LIFT SPRING REMOVAL WARNING: USE EYE AND HAND PROTECTION WHEN REMOVING SPRINGS, PERSONAL INJURY MAY RESULT. 1. Release and open decklid. 2. Support decklid on a suitable prop device. Fig. 5 3. Using a common pliers, disengage spring from rearward notch or hole under decklid opening side trough (Fig. 5). 4. Disengage spring from decklid hinge. INSTALLATION 1. Engage spring to decklid hinge. 2. Using a common pliers, connect spring to the rearward notch or hole under decklid opening side trough (Fig. 5). Without spoiler connect the spring into the hole. With spoiler connect spring to the notch. 3. Position spring with the damper at the of the spring with only 3 coils showing. 4. Remove decklid support device. 5. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair LATCH STRIKER REMOVAL 1. Release decklid latch and open decklid. 2. Remove push in fasteners attaching decklid lining to tail panel. 3. Remove trunk lining from tail panel. Fig. 4 4. Remove bolts attaching decklid latch striker to tail panel (Fig. 4). 5. Remove striker from vehicle. INSTALLATION 1. Install striker in vehicle. 2. Install trunk lining from tail panel. 3. Install push in fasteners attaching decklid lining to tail panel. 4. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6937 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6938 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6939 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6940 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6941 Fig. 35 Decklid - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6942 Decklid Release Switch (Power Release) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6943 Trunk / Liftgate Switch: Service and Repair DECKLID RELEASE SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry out on the deck lid release switch and pull out of instrument panel. 4. Disconnect the wiring connector. 5. Remove switch from vehicle. INSTALLATION 1. Connect the wiring connector. 2. Align switch in hole and firmly snap into place. 3. Close the glove box door. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES REMOVAL 1. Mark reference points before removing. 2. Using a heat gun gently apply heat in a circular motion to loosen the adhesive bond. 3. Using a nonmetallic prying device, such as a plastic or wood trim stick gently pry up at corners and remove. 4. Clean off all traces of adhesive or double sided tape from the panel with a general purpose adhesive remover. INSTALLATION 1. Clean panel surface with isopropyl alcohol. 2. Align badgeing to reference points. 3. Install and press securely to full adhesive contact. 4. Clean away any reference points. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE SCREEN REMOVAL 1. Release hood latch and open hood. 2. Remove windshield wiper arms. Fig. 1 3. Remove the five screws attaching cowl screen cover to just below windshield flange. (Fig. 1). 4. Remove cowl plenum to hood weatherstrip, at the leading edge of cowl cover. Pull weatherstrip towards the front of the vehicle to remove. 5. Remove cowl screen windshield seal from upper edge of the cowl screen cover. 6. Remove cowl screen cover from the vehicle. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 6951 Fig. 2 1. Place cowl screen cover into position on vehicle (Fig. 2). 2. Start five screws attaching cowl screen cover to cowl at base of windshield opening. 3. Install cowl screen windshield seal to upper edge of the cowl screen. 4. Push cowl plenum to hood weatherstrip, into position on the leading edge of cowl screen cover. 5. Install windshield wiper arms. 6. Tighten screws attaching cowl screen cover to cowl at base of windshield opening. 7. Install windshield wiper arms. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT END SPLASH SHIELDS REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove front wheel. Fig. 3 3. Remove push-in fasteners attaching splash shield to frame rail forward of suspension (Fig. 3). 4. Remove push in fasteners attaching splash shield to frame rail rearward of suspension. 5. Remove screws attaching wheelhouse splash shield to front fender. 6. Remove splash shield from vehicle. INSTALLATION 1. Place splash shield in position on vehicle. 2. Install screws attaching wheelhouse splash shield to front fender. 3. Install push in fasteners attaching splash shield to frame rail rearward of suspension. 4. Install push in fasteners attaching splash shield to frame rail forward of suspension. 5. Install front wheel. 6. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Remove the wheel. Fig. 10 2. Remove the two screws and the three push-pin fasteners (Fig. 10). INSTALLATION 1. Install the shield. 2. Install the three push-pin fasteners and two screws. 3. Install the wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation Front Cross-Member: Description and Operation FRONT CROSSMEMBER DESCRIPTION The front suspension crossmember must be properly installed to achieve design camber, caster settings and wheel stagger. The crossmember can be installed out of position on the frame rails due to its design. Bolts and cage nuts hold the rear of the crossmember to the frame torque boxes. Bolts and J-nuts hold the front of the crossmember to the frame rails. No designed in locating device is used to position the crossmember in the vehicle. Before removing the crossmember mark the frame torque box around the rear mounting location to aid installation. A crossmember that is removed during service must be installed in the same position from which it was removed. To verify that crossmember is in the proper position, refer to the dimensions provided. Front end dimensions are gauged from the principal locating point (PLP) holes located under the frame torque boxes rearward of the front wheels. After removal and installation of the crossmember is performed, verify that front suspension alignment is within specifications. If camber, caster settings and thrust angle are not within specifications, loosen and reposition crossmember to bring suspension within specifications. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 6966 Front Cross-Member: Service and Repair FRONT SUSPENSION CROSSMEMBER CAUTION: If the front suspension crossmember is being replaced due to collision damage, inspect the steering column lower coupling for damage. REMOVAL 1. Raise the vehicle. 2. Remove both front tire and wheel assemblies from the vehicle. Fig. 13 3. Remove both stabilizer bar links from the vehicle (Fig. 13). Remove each link by holding the upper retainer/nut with a wrench and turning the link bolt. 4. Remove the stabilizer bar cushion retainer bolts and retainers (Fig. 13), and remove the stabilizer bar with cushions attached from the vehicle. Fig. 14 5. Remove the nut and pinch bolt clamping each ball joint stud to the steering knuckle (Fig. 14). CAUTION: After removing the steering knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the steering knuckle outward at this point can separate the inner C/V joint on the driveshaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 6967 NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. Fig. 15 6. Separate each ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle (Fig. 15). 7. Remove the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler and can be accessed from above. Allow the cooler to hang out of the way. 8. Using wire or cord, support and tie off the power steering gear to the underbody of the vehicle, so when the crossmember is lowered, the gear does not fall away being held to the vehicle by only the steering column coupler and the fluid hoses. Fig. 16 9. Loosen and remove the four bolts attaching the power steering gear to the front suspension cross-member (Fig. 16). Remove the power steering gear from the front suspension crossmember. 10. Remove the drive-belt splash shield fasteners. Remove the shield. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 6968 Fig. 17 11. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle (Fig. 17). Remove the washer behind the strut from the torque strut bolt. 12. Remove the bolts mounting the engine torque strut in place (Fig. 17), then remove the engine torque strut from the vehicle. NOTE: Before removing the front suspension cross-member from the vehicle, the location of the cross-member must be scribed on the body of the vehicle (Fig. 9). Do this so that the crossmember can be relocated upon reinstallation against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost. Fig. 18 13. Using an awl, scribe a line (Fig. 18) marking the location of where the front suspension crossmember is mounted against the body of the vehicle. 14. Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 6969 Fig. 19 15. Loosen and completely remove the two front bolts (one right and one left) attaching the front suspension crossmember to the frame rails of vehicle. The right side bolt can be viewed in the mounting bolt figure (Fig. 19). The left side bolt is located in the same location on the other side of the vehicle. 16. Loosen the two rear bolts (one right and one left) attaching the front suspension crossmember and lower control arms to the body of the vehicle until they release from the threaded tapping plates in the body of the vehicle. Remove the rear bolts from the body of the vehicle, but do not completely remove the rear bolts because they are designed to disengage from the body threads yet stay within the lower control arm rear isolator bushing. This allows the lower control arm to stay in place on the crossmember. The right side bolt can be viewed in the mounting bolt figure (Fig. 19). The left side bolt is located in the same location on the other side of the vehicle. 17. Lower the front suspension crossmember. 18. Remove each lower control arm from the crossmember by removing the front pivot bolt. INSTALLATION CAUTION: If the front suspension crossmember is being replaced due to collision damage, inspect the steering column lower coupling for damage. 1. Install the lower control arms on the front suspension crossmember. Install the pivot bolts, but do not completely tighten them at this time. 2. Using the transmission jack, raise the front suspension crossmember and lower control arms until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the power steering gear into mounting position. 3. Start the two rear crossmember mounting bolts into the tapping plates mounted in the body. The right side bolt can be viewed in the mounting bolt figure (Fig. 19). The left side bolt is located in the same location on the other side of the vehicle. Next, install the two front mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all four mounting bolts to a approximately 2 N.m (20 in.lbs.) to hold the front suspension crossmember in position. NOTE: When reinstalling the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost. 4. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle (Fig. 18). Once the front suspension crossmember is correctly positioned, tighten the rear two crossmember mounting bolts to a torque of 203 N.m (150 ft.lbs.), then tighten the front two crossmember mounting bolts to a torque of 142 N.m (105 ft.lbs.). 5. Tighten the lower control arm front pivot bolts to a torque of 163 N.m (120 ft.lbs.). 6. Attach the steering gear to the front suspension crossmember (Fig. 16). Install the four power steering gear mounting bolts. Tighten the mounting bolts to a torque of 61 N.m (45 ft.lbs.). 7. Remove the wire or cord suspending the power steering gear to the underbody. 8. Install the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler. 9. Install each ball joint stud into the steering knuckle aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud. 10. Install a new ball joint stud pinch bolt and nut (Fig. 14). Tighten the nut to a torque of 95 N.m (70 ft.lbs.). 11. Install the engine torque strut and mounting bolts (Fig. 17). To properly align and tighten the torque strut, Refer to Engine Mount. 12. Install the washer on the end of the stud extending from the torque strut bolt (Fig. 17). 13. Install the pencil strut to the right front corner of the crossmember and body of the vehicle (Fig. 17). Tighten the pencil strut nuts to a torque of 58 N.m (43 ft.lbs.). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 6970 14. Install the drive-belt splash shield and fasteners. Fig. 20 NOTE: Before installing the stabilizer bar, make sure the bar is not upside-down. The stabilizer bar must be installed with the curve on the outboard ends of the bar facing downward to clear the control arms once fully installed (Fig. 20). 15. First, place the stabilizer bar in position on the front suspension crossmember. The slits in each cushion must point toward the front of the vehicle and sit directly on top of the raised beads formed into the stamping on the crossmember. Next, install the cushion retainers, matching the raised beads formed into the cushion retainers to the grooves formed into the cushions. Install the cushion retainer bolts, but do not completely tighten them at this time. 16. Install both stabilizer bar links back on vehicle (Fig. 13). Start each stabilizer bar link bolt with bushing from the bottom, through the stabilizer bar , inner link bushings, lower control arm, and into the upper retainer/nut and bushing. Do not fully tighten the link assemblies at this time. 17. Install the tire and wheel assemblies back on vehicle. Tighten the wheel mounting nuts to 135 N.m (100 ft.lbs.) torque. 18. Lower the vehicle. NOTE: It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height. 19. Tighten each stabilizer bar link by holding the upper retainer/nut with a wrench and turning the link bolt. Tighten each link bolt to a torque of 23 N.m (200 in.lbs.). 20. Tighten the stabilizer bar cushion retainer bolts to a torque of 34 N.m (300 in.lbs.). 21. Check the front wheel alignment on the vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair GRILLE REMOVAL 1. Release hood latch, open and support hood on prop rod. 2. Remove the fascia. Refer to Front Bumper. Fig. 6 3. Remove the nut and remove the emblem. (Fig. 6) 4. Using a trim stick C-4755 or equivalent, release the grille clips and remove the grille. 5. Using a trim stick C-4755 or equivalent, release the grille surround clips and remove the grille surrounds. IMPORT 1. Release hood latch, open and support hood on prop rod. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 6974 Fig. 7 2. Remove screws attaching grille to fascia (Fig. 7). 3. Pull grille away from fascia, reach between grille and fascia with pliers and compress lower grille clips. 4. Pull grille away from fascia and remove grille from vehicle. INSTALLATION 1. Install the grille and install the grille surrounds (Fig. 6). 2. Seat the all the retaining clips fully. 3. Install the emblem and install the nut. 4. Install the fascia. IMPORT 1. Align lower grille clips and center grille tab into fascia slots (Fig. 7). 2. Push lower grille forward until lower clips are seated into fascia slots. A click should be heard when clips are totally engaged into fascia slots. 3. Seat top of grille to fascia and install screws attaching grille to fascia. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats Carpet: Service and Repair Carpets and Floor Mats CARPETS AND FLOOR MATS REMOVAL For removal of the carpet, the carpet will need to be cut under the instrument panel. 1. Remove front seats. 2. Remove rear seat cushion. Fig. 4 3. Remove bolts attaching front seat belt lower anchors to floor (Fig. 4). 4. Remove door sill trim covers. 5. Remove cowl trim covers. 6. Remove center floor console. 7. Remove decklid release assist handle. 8. Remove lower fasteners from B-pillar trim panel. 9. Pull carpet from behind trim panel. 10. Fold carpet in half toward rear seat. 11. Remove carpet through rear door opening. INSTALLATION The new carpet must be cut for installation. The area is mark on the reverse side of the carpet. The location is in front of the tunnel area. 1. Install carpet through rear door opening. 2. Unfold carpet. 3. Tuck carpet behind trim panel. 4. Install lower fasteners holding B-pillar trim panel. 5. Install decklid release assist handle. 6. Install center floor console. 7. Install cowl trim covers. 8. Install door sill trim covers. 9. Install bolts attaching front seat belt lower anchors to floor. Tighten all seat belts to 40 N.m (30 ft.lbs.) torque. 10. Install rear seat cushion. 11. Install front seats. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 6980 Carpet: Service and Repair Trunk Lining TRUNK LINING REMOVAL Fig. 12 1. Remove fasteners (three per side) attaching carpet to shelf panel. Fasteners are accessed from inside the vehicle (Fig. 12). 2. Pull out leading flaps of the carpet through the opening from the shelf panel. 3. Pull carpet from under the springs. 4. Remove trunk carpet from vehicle. INSTALLATION 1. Place carpet in truck and smooth out. 2. Tuck both sides of the carpet ends under springs. 3. Position the leading flaps of the carpet through the opening onto the shelf panel. 4. Install fasteners (three per side) to secure the carpet to shelf panel (install fasteners from inside the vehicle). 5. Overlap the slits in the back of the carpet so the center section lays over the outer sections. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 Console: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures Console: Procedures REMOVAL 1. Fully apply parking brake. 2. Remove screw cover plugs over screws just rearward of cup holders. 3. Remove screws in cup holders attaching console to floor bracket. 4. Open console storage compartment lid, if so equipped. 5. Remove screws attaching console to floor bracket. 6. Remove shift lever knob, if vehicle is equipped with a manual transmission. 7. Lift console upward over gear selector and park brake handle. 8. Remove console from vehicle. INSTALLATION 1. Place floor console into position in vehicle. 2. Install screws attaching console to floor brackets. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 7011 3. Install shift lever knob, if vehicle is equipped with a manual transmission. 4. Release parking brake. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 7012 Console: Removal and Replacement FLOOR CONSOLE REMOVAL 1. Fully apply parking brake. 2. Remove screw cover plugs over screws just rearward of cup holders. Fig. 7 3. Remove screws in cup holders attaching console to floor bracket (Fig. 7). 4. Open console storage compartment lid, if so equipped. 5. Remove screws attaching console to floor bracket. 6. Remove shift lever knob, if vehicle is equipped with a manual transmission. 7. Lift console upward over gear selector and park brake handle. 8. Remove console from vehicle. INSTALLATION 1. Place floor console into position in vehicle. 2. Install screws attaching console to floor brackets. 3. Install shift lever knob, if vehicle is equipped with a manual transmission. 4. Release parking brake. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7017 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Application and ID Glove Compartment: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Glove Compartment ............................................................................................................................ .................................................................. T194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement Glove Compartment: Removal and Replacement GLOVE BOX REMOVAL 1. Remove three glove box door hinge screws. 2. Open glove box and remove assembly from vehicle. 3. Remove the latch by gently prying the retainer clip out of its slot. 4. Remove nine screws retaining glove box door to bin assembly. 5. Remove glove box door from bin and remove. 6. Remove dampers by gently stretching them over the end of their pins. INSTALLATION 1. Assemble glove box door and bin. 2. Install the nine screws retaining glove box door to bin assembly. 3. Install the latch using retainer clip. 4. Install glove box dampers over end of pins. 5. Place glove box into instrument panel opening. 6. Close glove box door and install the three glove box door hinge screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 7023 Glove Compartment: Overhaul REMOVAL 1. Remove three glove box door hinge screws. 2. Open glove box and remove assembly from vehicle. 3. Remove the latch by gently prying the retainer clip out of its slot. 4. Remove eight screws retaining glove box door to bin assembly. 5. Separate glove box door from bin and remove. 6. Remove dampers by gently stretching them over the end of their pins. INSTALLATION 1. Assemble glove box door and bin. 2. Install the eight screws retaining glove box door to bin assembly. 3. Install the latch using retainer clip. 4. Install glove box dampers over end of pins. 5. Place glove box into instrument panel opening. 6. Close glove box door and install the three glove box door hinge screws. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER REMOVAL 1. Remove screws attaching sun visors to roof header panel. 2. Disconnect wire connector from lighted vanity mirror, if so equipped. 3. Remove sun visors from vehicle. 4. Remove A-pillar trim covers. 5. Remove B-pillar trim panels. 6. Remove (upper) quarter panel trim panels. 7. Remove assist handle, if so equipped. 8. Remove sun visor hooks. 9. Remove coat hooks, if so equipped. 10. Remove three push in fasteners at rear of headliner. 11. Disengage dome lamp wire connector, at rear of headliner. 12. Remove push in fastener attaching wiring to C-pillar. Fig. 8 13. Remove headliner through door opening (Fig. 8). INSTALLATION 1. Position headliner in vehicle. 2. Install sun visor hooks, if so equipped. 3. Install coat hooks, if so equipped. 4. Install three push in fastener at rear of headliner. 5. Install assist handles, if so equipped. 6. Install push in fastener attaching headliner wiring to C-pillar. 7. Connect dome lamp wire connector, at rear of headliner. 8. Install (upper) quarter panel trim panel. 9. Install B-pillar trim panels. 10. Install A-pillar trim covers. 11. Install sun visors, lighted vanity mirror wire connector, if so equipped, and screws attaching sun visors to roof header panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair Rear Shelf: Service and Repair REAR SHELF TRIM PANEL REMOVAL 1. Remove quarter trim panels as necessary, Refer to Trim Panel. 2. Remove rear seat cushion and back. 3. Disengage seat belt bezels from rear shelf trim panel. 4. Remove rear seat shoulder belt from the shelf by sliding belt through the slot. Fig. 9 5. Remove rear shelf trim panel from vehicle (Fig. 9). INSTALLATION 1. Place into position rear shelf trim panel. 2. Slide the rear seat shoulder belt through the slot in the rear shelf trim panel. 3. Engage seat belt bezels to rear shelf trim panel. 4. Install rear seat cushion and back. 5. Install quarter trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair SUN VISOR All vehicles with driver and passenger side airbags must have a colored coded five Bullet point airbag warning label applied to the sun visor, verify label availability and ensure the label is installed. REMOVAL 1. Remove sun visor from center support. 2. Remove screws attaching sun visor to roof header. 3. Remove sun visor from header. 4. If equipped, disconnect wire connector from body harness. 5. Remove sun visor from vehicle. INSTALLATION 1. Place sun visor in position. 2. If equipped, connect wire connector from body harness. 3. Install screws attaching sun visor to header. 4. Install sun visor into center support. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7037 Trim Panel: Removal and Replacement Door Sill Trim Panel DOOR SILL TRIM REMOVAL 1. Open door to gain access to sill trim. 2. Disengage clips attaching sill trim to door sill and door opening flange. Fig. 5 Fig. 6 3. Remove door sill trim from vehicle (Fig. 5) and (Fig. 6). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7038 INSTALLATION 1. Position door sill trim on door sill. 2. Align locating pins on backside of trim panel to holes in door sill. 3. Engage clips on trim panel into slots in door sill. 4. Engage clips on trim panel onto door opening flange. 5. Press downward on trim panel to fully engage all clips. Front Door Trim Panel TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Lower door glass. Fig. 13 3. Remove window regulator crank, if so equipped (Fig. 13). Fig. 11 4. Remove screw from inside arm rest pull cup (Fig. 11). 5. Remove screw from behind inside latch release handle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7039 6. Disengage push-in fasteners attaching trim to door panel around perimeter of trim panel. 7. Tilt trim panel outward to clear locator pins on backside of trim panel. 8. Disconnect trim panel from retainer channel in inner belt weatherstrip at top of door by lifting while gently jiggling. 9. Move trim panel away from door and disengage clip attaching latch rod to handle. 10. Remove latch rod from handle. CAUTION: Do not allow door trim panel to hang by the wire connector or wiring. 11. Disconnect wire connector from power door lock switch, mirror switch, and power window switch if so equipped. 12. Remove trim panel from door. INSTALLATION 1. Replace any damaged or missing push in fasteners from around perimeter of door trim panel. 2. Place trim panel near door. 3. Connect wire connector into power door lock switch, mirror switch, and power window switch , if so equipped. 4. Insert latch rod into handle and engage clip. 5. Install trim panel into retainer channel at top of door and push down to seat. 6. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 7. Install push in fasteners to hold trim to door panel around perimeter of trim panel. 8. Install screw inside latch release handle. 9. Install screw inside arm rest pull cup. 10. With the window in the down position, 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 so equipped. A-Pillar Trim A-PILLAR TRIM REMOVAL 1. Disengage clips holding trim to A-pillar. Fig. 1 2. Separate A-pillar trim from vehicle (Fig. 1). INSTALLATION 1. Position A-pillar trim panel to A-pillar. 2. Align locating pins on backside of trim panel to mating holes in A-pillar. 3. Push clips on trim panel into slots in A-pillar. B-Pillar Trim B-PILLAR TRIM REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7040 Fig. 2 1. Remove bolt attaching lower seat belt anchor to floor pan kick-up (Fig. 2). 2. Remove shoulder belt height control knob. 3. Remove turning loop cover. 4. Remove bolt and remove the turning loop. Fig. 3 5. Remove bolt attaching turning loop to belt adjuster (Fig. 3). 6. Remove access cover from B-pillar trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7041 7. Disengage clips attaching trim to B-pillar. 8. Feed seat belt turning loop and seat belt through trim panel. 9. Remove B-pillar trim from vehicle. INSTALLATION NOTE: Tighten all seat belt bolts to 40 N.m (30 ft.lbs.) torque. 1. Position B-pillar trim panel near B-pillar. 2. Feed seat belt turning loop and seat belt through trim panel. 3. Align locating pins on backside of trim panel to mating holes in B-pillar. 4. Push clips on trim panel into slots in B-pillar. 5. Install access cover to B-pillar trim. 6. Install bolt attaching turning loop to belt adjuster. 7. Install the turning loop cover. 8. Move adjuster in to the lowest position. 9. Install shoulder belt height control knob. 10. Install bolt attaching lower seat belt anchor to floor pan kick-up. Lower Quarter Trim Panel LOWER QUARTER TRIM REMOVAL 1. Remove upper quarter trim panel. 2. Remove rear seat cushion and back. 3. Disengage clips attaching trim to lower quarter panel. 4. Remove seat belt from slot in trim panel. Fig. 13 5. Remove lower quarter trim from vehicle (Fig.13). INSTALLATION 1. Position lower quarter trim panel to vehicle. 2. Install seat belt to slot in trim panel. 3. Align locating pins on backside of trim panel to mating holes in inner quarter panel. 4. Press clips on trim panel into slots in inner quarter panel. 5. Install rear seat back and cushion. 6. Install upper quarter trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7042 Upper Quarter Trim UPPER QUARTER TRIM REMOVAL Fig. 13 1. Disengage clips attaching trim to upper quarter panel (Fig. 13). 2. Remove upper trim panel from vehicle. INSTALLATION 1. Check to ensure that electric rear window wiring is positioned correctly in the roof channel provided. 2. Position trim panel in vehicle. 3. Align locating pins on backside of trim panel to mating holes in upper quarter panel. 4. Push clips on trim panel into slots in upper quarter panel. Rear Door Trim Panel REMOVAL 1. Release door latch and open door. 2. Lower window glass 3. Remove window regulator crank. 4. Remove screw from inside arm rest pull cup. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7043 Fig. 6 Rear Door Trim 5. Remove screw from behind inside latch release handle. 6. Disengage push in fasteners attaching trim to door panel around perimeter of trim panel. 7. Disengage push-in metal spring clip holding trim in sail flag area. 8. Lift trim panel up off belt weatherstrip. 9. Tilt top of trim panel away from door and disengage clip attaching latch rod to handle. 10. Remove latch rod from handle. 11. Remove trim panel from door. INSTALLATION 1. Replace any damaged or missing push in fasteners from around perimeter of door trim panel. 2. Place trim panel in position on door. 3. Insert latch rod into handle and engage clip. 4. Engage trim panel into retainer channel at top of door. 5. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 6. Engage push in fasteners attaching trim to door panel around perimeter of trim panel. 7. Install screw behind inside latch release handle. 8. Install screw inside arm rest pull cup. 9. Install window regulator crank. Rear Shelf Trim Panel REAR SHELF TRIM PANEL REMOVAL 1. Remove quarter trim panels as necessary, Refer to Trim Panel. 2. Remove rear seat cushion and back. 3. Disengage seat belt bezels from rear shelf trim panel. 4. Remove rear seat shoulder belt from the shelf by sliding belt through the slot. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7044 Fig. 9 5. Remove rear shelf trim panel from vehicle (Fig. 9). INSTALLATION 1. Place into position rear shelf trim panel. 2. Slide the rear seat shoulder belt through the slot in the rear shelf trim panel. 3. Engage seat belt bezels to rear shelf trim panel. 4. Install rear seat cushion and back. 5. Install quarter trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove door trim panel and water dam. 2. Close door glass. 3. Disconnect door lock rod from latch. 4. Remove clip attaching lock cylinder to door handle. Fig. 10 5. Pull lock cylinder from door handle (Fig. 10). INSTALLATION 1. Push lock cylinder into door handle. 2. Install clip attaching lock cylinder to door handle. 3. Connect door lock rod from latch. 4. Install door trim panel and water dam. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 7053 Right Cylinder Lock Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System Inadvertent Siren Activation Keyless Entry Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System Inadvertent Siren Activation > Page 7063 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 7069 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7072 Keyless Entry Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7073 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7074 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7075 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7076 Remote Keyless Entry Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7077 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE There are 2 Remote Keyless Entry Modules for the 2002 module year, premium and base. The base module is for a vehicle with power door locks only. The base module performs the same functions that the premium module does but has no provisions for Vehicle Theft Security System (VTSS) or Remote Keyless Entry. Both modules communicate with other modules via the PCI bus circuit. The module monitors the Airbag Control Module messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message, along with the verification that the ignition is on, it will provide the "enhanced accident response feature". This feature will cause the module to unlock all doors and the instrument cluster to turn the courtesy lamps ON. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message and receive body style information. The Base module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the driver or passenger (BUX) cylinder lock switch. The premium module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the RKE transmitter. Two RKE transmitters are supplied with a premium equipped vehicle but a total of 4 can be programmed to the module. Horn chirp on a premium equipped vehicle is customer programmable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7078 Keyless Entry Module: Testing and Inspection For procedures on diagnosing and testing the RKE Module's RKE functions, refer to the proper Body Diagnostic Procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation Fig.1 Remote Keyless Entry Transmitter The Remote Keyless Entry (RKE) system Radio Frequency (RF) transmitter is equipped with four buttons, labeled LOCK, UNLOCK, DECK LID RELEASE, and PANIC. It is also equipped with a key ring and is designed to serve as a key fob. The operating range of the transmitter radio signal is up to 10 meters (30 feet) from the RKE receiver. Each RKE transmitter has a different vehicle access code, which must be programmed into the memory of the RKE receiver in the vehicle in order to operate the RKE system. Two transmitters are provided with the vehicle, but the RKE receiver can retain the access codes of up to four transmitters in its memory. The RKE transmitter operates on two Panasonic CR2016 (or equivalent) batteries. Typical battery life is from one to two years. The RKE transmitter cannot be repaired and, if faulty or damaged, it must be replaced. The transmitter has four buttons for operation. They are LOCK, UNLOCK, DECK LID RELEASE, and PANIC. - The UNLOCK button will unlock the driver's door, flash the park lamps twice and enable illuminated entry. Pushing and releasing the button once will unlock the driver's door. Pushing and releasing the button two times, within a five second interval, will unlock all doors. - Upon pressing the LOCK button, the horn will sound a short CHIRP (if enabled) and flash the park lamps to notify that the all door lock signal was received and set. Illuminated entry is cancelled and the interior lamps are faded to OFF. - Pushing and releasing the DECK LID RELEASE button two times within a five second interval, will slightly ajar the deck lid. - Pushing and holding the PANIC button will cause the panic alarm to sound for three minutes, until the panic button is pressed and held a second time, or the vehicle reaches a speed of 15 mph. The receiver is capable of retaining a Vehicle Access Code (VAC) even when power is removed. Each Remote Keyless Entry (RKE) module must have at least one and no more than four transmitters. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming Keyless Entry Transmitter: Service and Repair Transmitter Programming STANDARD PROCEDURE - TRANSMITTER PROGRAMMING The Remote Keyless Entry transmitters can be programmed with the use of the DRB III scan tool or by the customer. DRB III Programming When Using The DRB III Scan Tool, SELECT: 1. "Theft Alarm" 2. "VTSS" 3. "Miscellaneous" and then the desired function. Customer Programming For a customer to be able to program RKE transmitters themselves, at least one RKE transmitter must be programmed already This procedure is to add additional transmitters. If all transmitters are lost, the DRB III scan tool must be used to program the new transmitters. 1. Insert the key into the ignition switch, and turn the ignition switch to the RUN position (without starting the vehicle). 2. Using the RKE transmitter programmed to the RKE module, press and continuously hold down the UNLOCK button for 4 - 10 seconds. 3. Within the 4 10 second time range, continue to hold the UNLOCK button and press the PANIC button. Both buttons may then be released. Upon the PANIC button being depressed, the message for customer programming mode will be transmitted to the RKE module. 4. A chime will be heard to verify that the customer programming mode has been entered. 5. Press and release any button on each transmitter that is to be programmed to the RKE module, including any transmitters which were previously programmed to the RKE module (with a maximum of four possible). After each transmitter is successfully programmed, a chime will be heard to verify that successful programming of the transmitter has occurred. 6. After 30 seconds, or upon the ignition switch being turned OFF, a chime will indicate that the RKE module has exited the programming mode. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 7084 Keyless Entry Transmitter: Service and Repair Keyless Entry Transmitter Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Disconnect wire connector. 4. Remove two attaching screws. 5. Remove the switch from the door panel. INSTALLATION 1. Install the switch to the door panel. 2. Install the two attaching screws. 3. Connect the one wire connector. 4. Install the front door trim panel. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 7089 Right Cylinder Lock Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations > Page 7094 Power Door Lock Actuator: Connector Locations Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations > Page 7095 Fig. 23 Door (Rear) - LHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations > Page 7096 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 7097 Power Door Lock Actuator: Diagrams Driver Door Lock Motor/Ajar Switch Left Rear Door Loack Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Right Rear Door Lock Motor/Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 7098 Power Door Lock Actuator: Testing and Inspection 1. Make certain battery is in normal condition and fuses powering the RKE module aren't blown before circuits are tested. 2. 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. 3. In the event that none of the motors work, the problem may be caused by a shorted motor, a bad switch or a bad relay internal to the RKE module. Disconnecting a defective motor will allow the others to work. 4. To test an individual door lock motor, disconnect the electrical connector from the motor. 5. To lock the door, connect a 12 volt power source to one pin of the lock motor and a ground wire to the other pin. 6. To unlock the door, reverse the wire connections at the motor pin terminals. 7. If these results are NOT obtained, replace the motor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Door (Driver) - LHD Door (Passenger) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7102 Door (Passenger) - RHD Fig. 61 Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7103 Fig. 62 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7104 Power Door Lock Switch: Diagrams Left Door Lock Switch Passenger Door Lock Motor/Ajar Switch Right Door Lock Switch Right Rear Door Lock Motor/Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7105 Power Door Lock Switch: Testing and Inspection 1. Remove the switch from its mounting location, and disconnect from vehicle wiring harness. (Refer to POWER LOCKS/POWER LOCK SWITCH - REMOVAL). Door Lock Switch Resistance 2. Using an ohmmeter, refer to the DOOR LOCK SWITCH RESISTANCE table to determine if switch resistance is correct in the Lock and Unlock switch positions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7106 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. RKE Module Location 3. Remove the two screws holding the RKE module to the instrument panel assembly. 4. Slide locking tab of the wiring connector sideways to unlock tab, and remove connector from RKE module. 5. Remove RKE module from vehicle. NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Additionally, all transmitters must be reprogrammed to the new RKE module. 1. Install the RKE module into the vehicle. 2. Connect the RKE wiring connector. 3. Install the two screws holding the RKE module to the instrument panel assembly. 4. Install the instrument panel top cover. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL Fig. 2 1. Remove decklid latch. 2. Remove clip attaching decklid lock cylinder to decklid. 3. Pull lock cylinder from decklid (Fig. 2). INSTALLATION 1. Place lock cylinder into position. 2. Install clip attaching decklid lock cylinder to decklid. 3. Install decklid latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Door (Driver) - LHD Fig. 61 Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7114 Power Mirror Switch: Diagrams Power Mirror Switch (LHD) Power Mirror Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test Power Mirror Switch: Testing and Inspection Power Foldaway Mirror Switch Test The following test is designed to be used only on vehicles equipped with power fold-away side view mirrors. 1. Remove power mirror switch from mounting position (Refer to POWER MIRRORS/POWER FOLDAWAY MIRROR SWITCH - REMOVAL). Fig.2 Power Fold-Away Mirror Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the tables below. NOTE: When testing using the chart below be certain to read the chart correctly. Example - When testing left mirror "DOWN", pins 1, 9,10 will show continuity to each other, and pins 3, 4, 5 will show continuity to each other. 3. If test results are not obtained as shown in the tables below, replace the switch. Extended Mirror Switch Circuit Test Extended Mirror Switch Circuit Test NOTE: MIRROR POSITION SWITCH MUST BE IN THE "UNFOLD" POSITION TO USE CHART. Retracted Mirror Switch Circuit Test Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 7117 Retracted Mirror Switch Circuit Test NOTE: MIRROR POSITION SWITCH MUST BE IN THE "FOLD" POSITION TO USE CHART. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 7118 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove power mirror switch 2. Disconnect wiring harness connector from switch. Power Mirror Switch Table ( Part 1 Of 2 ) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 7119 Power Mirror Switch Table ( Part 2 Of 2 ) 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 7120 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on window switch bezel and remove from door trim panel. 3. Disconnect wire connector from switch. 4. Remove two switch retaining screws. INSTALLATION 1. Install the retaining screws. 2. Reconnect the wire connector to the switch. 3. Insert switch into door trim panel 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID Exterior Colors Interior Colors Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 7125 Paint: Description and Operation BASE COAT/CLEAR COAT FINISH DESCRIPTION On most vehicles a two-part paint application (basecoat / clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT SURFACE TOUCH-UP DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar(R) Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. Refer to Information Labels. WARNING: USE AN OSHA APPROVED RESPIRATOR AND SAFETY GLASSES WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. TOUCH UP PROCEDURE 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar(R) Tar/Road Oil Remover, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat. WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL - BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 7128 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING/BUFFING & POLISHING DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: Customer Interest Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 7138 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation Keyless Entry Module: All Technical Service Bulletins Alarm System - Inadvertent Siren Activation NUMBER: 08-012-03 GROUP: Electrical DATE: Apr. 25, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MAY 9, 2003. SUBJECT: Inadvertent Siren Activation OVERVIEW: This bulletin involves replacing and configuring an Alarm Remote Keyless Entry Module (ARKEM). MODELS: 2002 (PG) PT Cruiser (International Markets) 2000 - 2003 (PL) NEON (International Markets) 2001 - 2003 (PT) PT Cruiser (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A THATCHAM ALARM, SALES CODE LSC. SYMPTOM/CONDITION: Customer may describe inadvertent siren activation or security alarm activates for no apparent reason, can happen at any time. DIAGNOSIS: If this condition can be duplicated or customer describes this condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: AFTER INSTALLING A NEW ARKEM (RKE) MODULE IT MUST BE CONFIGURED USING THE DRBIII(R) SCAN TOOL AS DESCRIBED BELOW. THE DRBIII(R) SCAN TOOL MUST BE OPERATING AT LEVEL 56.0 OR HIGHER. 1. Replace the ARKEM (RKE) module as described in the appropriate service manual. 2. Hook up the DRBIII(R) Scan Tool to the Data Link Connector (DLC). 3. With the key in the ignition, turn the key to the RUN position. 4. After the DRBIII(R) Scan Tool initialization, perform the following: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 08-012-03 > Apr > 03 > Alarm System - Inadvertent Siren Activation > Page 7144 a. Select "Theft Alarm". b. Select "VTSS". c. Select "Miscellaneous". d. Select "Configure Module". e. Select "Yes" for Current Configuration Display. f. Press Any key. g. Select the number of the model year of the vehicle (new requirement). h. Select the number of the body style of the vehicle. i. Select the number for Left Hand Drive or Right Hand Drive. j. Select the number of the Market. k. Select the Desired VTA (module) Type. l. The Current Configuration is displayed. m. Reprogram the RKE (Key Fob) Transmitter(s). 5. The configuration is complete, disconnect the DRBIII(R) Scan Tool. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7147 Keyless Entry Module: Connector Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7148 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7149 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 7150 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7151 Remote Keyless Entry Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7152 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE There are 2 Remote Keyless Entry Modules for the 2002 module year, premium and base. The base module is for a vehicle with power door locks only. The base module performs the same functions that the premium module does but has no provisions for Vehicle Theft Security System (VTSS) or Remote Keyless Entry. Both modules communicate with other modules via the PCI bus circuit. The module monitors the Airbag Control Module messages for the purpose of monitoring the deployment of the airbag. Upon receiving that message, along with the verification that the ignition is on, it will provide the "enhanced accident response feature". This feature will cause the module to unlock all doors and the instrument cluster to turn the courtesy lamps ON. The RKE module communicates with the Powertrain Control Module to receive vehicle speed information to activate the rolling door lock feature, receive the "okay to lock" message and receive body style information. The Base module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the driver or passenger (BUX) cylinder lock switch. The premium module wakes up the Instrument Cluster to turn ON the illuminated entry when it senses a signal from the RKE transmitter. Two RKE transmitters are supplied with a premium equipped vehicle but a total of 4 can be programmed to the module. Horn chirp on a premium equipped vehicle is customer programmable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7153 Keyless Entry Module: Testing and Inspection For procedures on diagnosing and testing the RKE Module's RKE functions, refer to the proper Body Diagnostic Procedures. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module Sunroof / Moonroof Module: Service and Repair Sunroof Module REMOVAL Fig. 1 Sunroof Components 1. Remove sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Disengage front door weatherstrip from headliner, pull headliner down to access control unit. 2. Disconnect wire connector from control unit. 3. Slide control unit up and forward and remove. INSTALLATION 1. Place sunroof control unit into position. 2. Lock control unit into position. 3. Connect wire connector to control unit. 4. Install sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Engage front door weatherstrip to headliner. 5. Cycle sunroof to the full open position. 6. Ensure sunroof adjustment. Refer to Sunroof Glass Adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 7159 Sunroof / Moonroof Module: Service and Repair Sunroof Module Assembly REMOVAL 1. Close glass panel, if possible 2. Remove A-pillar trim. 3. Remove upper B-pillar and C-pillar trim. Fig. 1 Sunroof Components 4. Remove sunroof welt. 5. Remove the switch. 6. Detach fastener from headlinder bracket to the front beam. 7. Remove all assist handles. 8. Remove sun visors. 9. Remove headlining and disconnect the dome lamp connector. 10. Disconnect sunroof motor wiring connector. 11. Disconnect drain tubes. 12. Remove fasteners attaching sunroof module to vehicle roof. 13. With the aid of a helper, remove sunroof module from roof. 14. Remove sunroof module from vehicle. INSTALLATION 1. With the aid of a helper, position sunroof module in vehicle. 2. Install fasteners attaching sunroof module to vehicle roof and support braces. Tighten all fasteners to 5 Nm (44 in. lbs.), starting from the front and working rearward and then the motor bracket. 3. Connect drain tubes. 4. Connect sunroof motor wiring connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 7160 5. Headliner in position connect dome lamp wire connector. Install headlining. 6. Install the fastener from the headliner bracket to front beam. 7. Install switch. 8. Install sunroof welt. 9. Install B-pillar and C-pillar trim. 10. Install A-pillar trim. 11. Install sun visors. 12. Install all assist handles. 13. Install sunroof sunshade. 14. Install sunroof glass panel. 15. Cycle glass panel open and close. 16. Ensure glass adjustment, refer to Glass Adjustment procedure 17. Verify correct operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair REMOVAL 1. Open sunroof glass panel to the vent position. Fig. 1 Sunroof Components 2. Through the glass panel opening, disengage the two rear slide blocks of sunshade from sunshade guide. 3. Slide the sunshade rearward to have access to the two front slide blocks of sunshade and disengage sunshade from sunshade guide. 4. Lift sunshade out of sunshade guide. INSTALLATION 1. Place sunshade with cloth side down and install one side's slide blocks into the track on the sunshade guide. 2. Slide the other side's slide blocks to fully inward position and insert them into the sunshade guide. 3. Verify that all four slide blocks are fully engaged in the sunshade guide. 4. Slide sunshade fully rearward and forward to verify operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Description and Operation Sunroof / Moonroof Limit Switch: Description and Operation LIMIT SWITCH DESCRIPTION The Sunroof Limit Switch is located in the drive motor assembly housing and is not serviceable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Sunroof Motor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 7172 Sunroof / Moonroof Motor: Testing and Inspection ADJUSTMENTS ADJUSTMENTS - SUNROOF VENT POSITION PLACING SUNROOF GLASS IN VENT POSITION 1. Remove the drive motor. 2. Remove sunroof glass panel. Fig. 2 3. Slide the mechanism forward till the mechanism slide is parallel with the front edge of the guide (Fig. 2). Fig. 3 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 7173 Fig. 4 4. Using a rule, measure the rear end of the mechanism to the guide on each side of sun roof (Fig. 3) or (Fig. 4). 5. Initial height should be 44 to 48 mm. Adjust mechanism so that both sides are dia 1.0 mm of each other. 6. Install drive motor. 7. Install sunroof panel. 8. Ensure glass adjustment. RE-POSITIONING DRIVE MOTOR If the drive motor is not in the correct position it can be adjusted to the correct position when the sunroof glass is in the vent position. Remove the drive motor from the sunroof module, reconnect the wires to the motor and press the motor switch to the vent position. This should place the drive motor into the vent position. The motor may now be installed if the sunroof glass panel is in the vent position Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation Sunroof / Moonroof Motor: Service and Repair Removal and Installation SUNROOF DRIVE MOTOR REMOVAL NOTE: The Drive Motor is shipped in the VENT position. If the sunroof glass is not in the VENT position, it must be moved to the VENT position. If the drive motor and/or the sunroof mechanism is not in the VENT positions, the sunroof vent height will not be correct. 1. If the drive motor is to be reused, cycle the sunroof glass to the VENT position, if possible. Fig. 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation > Page 7176 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation > Page 7177 2. Remove sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Disengage front door weatherstrip from headliner, pull headliner down to access sunroof drive motor (Fig. 1). 3. Disconnect wire harness connector from motor. 4. Remove the three screws attaching drive motor to sunroof module bracket. 5. Remove drive motor from bracket from the front beam. INSTALLATION 1. If the drive motor and/or sunroof glass is not in the VENT position. 2. Place drive motor into position on the front beam. 3. If glass panel is mounted, with the aid of a helper, hold the sunroof glass panel in the VENT position while installing the motor. 4. Install screws attaching drive motor to motor bracket. 5. Connect wire harness to drive motor. 6. Install sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Engage front door weatherstrip to headliner. 7. Ensure sunroof adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation > Page 7178 Sunroof / Moonroof Motor: Service and Repair Sunroof Drive Motor SUNROOF DRIVE MOTOR REMOVAL NOTE: The Drive Motor is shipped in the VENT position. If the sunroof glass is not in the VENT position, it must be moved to the VENT position. Refer to Placing The Sunroof Glass Into The VENT Position. If the drive motor and/or the sunroof mechanism is not in the VENT positions, the sunroof vent height will not be correct. Refer to Placing The Sunroof Glass Into The VENT Position and/or Placing Drive Motor Into The VENT Position. 1. If the drive motor is to be reused, cycle the sunroof glass to the VENT position, if possible. Fig. 1 2. Remove sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Disengage front door weatherstrip from headliner, pull headliner down to access sunroof drive motor (Fig. 1). 3. Disconnect wire harness connector from motor. 4. Remove the three screws attaching drive motor to sunroof module bracket. 5. Remove drive motor from bracket from the front beam. INSTALLATION 1. If the drive motor and/or sunroof glass is not in the VENT position, refer to Placing The Sunroof Glass Into The VENT Position and/or Placing Drive Motor Into The VENT Position. 2. Place drive motor into position on the front beam. 3. If glass panel is mounted, with the aid of a helper, hold the sunroof glass panel in the VENT position while installing the motor. 4. Install screws attaching drive motor to motor bracket. 5. Connect wire harness to drive motor. 6. Install sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Engage front door weatherstrip to headliner. 7. Ensure sunroof adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Sunroof Switch Sunroof Vent Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close Sunroof / Moonroof Track: Customer Interest Body - Sunroof Vents Only/Won't Open or Close NUMBER: 23-049-04 REV. A GROUP: Body DATE: December 15, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS RELATED TO THIS BULLETIN UNTIL AFTER DECEMBER 31, 2004. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-049-04, DATED NOVEMBER 22, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEARS, REPAIR INFORMATION AND PARTS. SUBJECT: Sunroof Vents But Will Not Open/Close OVERVIEW: This bulletin involves disassembling and reassembling the sunroof mechanism **and possibly replacing the locker slide(s).**. MODELS: **2000** - 2005 (PL) Neon/SRT4 NOTE: SYMPTOM/CONDITION: The sunroof may go to vent and close but will not go to open or the sunroof goes to vent position but will not close or open. These Symptoms occur after the sunroof has been operated at fast highway speeds which applies force to the sunroof mechanism and causes it to go "over-center" and bind usually on one side but could be both sides. DIAGNOSIS: If the vehicle operator describes the above Symptom/Condition, perform the Repair Procedure. **PARTS REQUIRED: REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7190 1. Position the sunroof sunshade in the full rearward position. 2. Position the glass reinforcement panel in the CLOSED position before removing the six mounting screws. 3. Remove the six sunroof glass panel screws. 4. Push the glass panel upward from the underside until the glass panel clears the roof panel. 5. Lift glass panel from the vehicle. 6. Put the sunroof mechanism in the vent position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7191 7. Using punch with diameter slightly smaller than the pin in mechanism (about 3 mm dia.), push the pin out of the mechanism, (Fig. 2). 8. Pull up on mechanism bracket. **and remove the locker slide only if broken, if the locker slide is not broken then skip to step 10). 9. Hold appropriate (right or left) replacement locker slide from kit p/n 05174865AA, and insert into mechanism bracket.** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7192 10. Make sure main lever is in the correct position, (Fig. 3). If the main lever is in the up position before the pin/block, (Fig. 4), it means the module is mistimed (symptoms for this are that the module will go to vent, but will not open). 11. If the sunroof is mistimed, move the sunroof to the closed position and carefully move the mechanism into the vent position (by using the switch), guiding the main lever so the pin/block goes into the slot/track of the main lever. 12. Push the locker slide all the way back in the mechanism bracket. 13. Align the main lever, bushing and locker slide, (Fig. 5), by pushing down on the bracket and pulling forward on the main lever. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7193 14. Gently install the pin from the inside of the opening. Push the pin in with punch until the pin is flush with the face of the locker slide side of the mechanism bracket opening (outboard side). **If the pin or bushing become lost or damaged replacements are available in kit p/n 05174865AA. 15. Repeat steps 6 - 14 for the other side if necessary. 16. Make sure the locker slides are engaged and cycle the sunroof to the close position, 17. Position the glass panel in the roof opening. 18. Start, but do not tighten, the glass attachment screws. ** 19. Using a business card as a guide, slide the card around the edge of glass panel to ensure panel is centered in the opening. 20. Position the front of the sunroof glass panel so that the corners are flush to 1.0 mm below the top surface of the roof panel. 21. Position the rear of the sunroof glass panel so that the corners are flush to 1.0 mm over flush to the top surface of the roof panel. 22. With the aid of a helper, hold the glass panel in position and tighten glass attaching screws. 23. Cycle the sunroof and verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close Sunroof / Moonroof Track: All Technical Service Bulletins Body - Sunroof Vents Only/Won't Open or Close NUMBER: 23-049-04 REV. A GROUP: Body DATE: December 15, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS RELATED TO THIS BULLETIN UNTIL AFTER DECEMBER 31, 2004. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-049-04, DATED NOVEMBER 22, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEARS, REPAIR INFORMATION AND PARTS. SUBJECT: Sunroof Vents But Will Not Open/Close OVERVIEW: This bulletin involves disassembling and reassembling the sunroof mechanism **and possibly replacing the locker slide(s).**. MODELS: **2000** - 2005 (PL) Neon/SRT4 NOTE: SYMPTOM/CONDITION: The sunroof may go to vent and close but will not go to open or the sunroof goes to vent position but will not close or open. These Symptoms occur after the sunroof has been operated at fast highway speeds which applies force to the sunroof mechanism and causes it to go "over-center" and bind usually on one side but could be both sides. DIAGNOSIS: If the vehicle operator describes the above Symptom/Condition, perform the Repair Procedure. **PARTS REQUIRED: REPAIR PROCEDURE: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7199 1. Position the sunroof sunshade in the full rearward position. 2. Position the glass reinforcement panel in the CLOSED position before removing the six mounting screws. 3. Remove the six sunroof glass panel screws. 4. Push the glass panel upward from the underside until the glass panel clears the roof panel. 5. Lift glass panel from the vehicle. 6. Put the sunroof mechanism in the vent position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7200 7. Using punch with diameter slightly smaller than the pin in mechanism (about 3 mm dia.), push the pin out of the mechanism, (Fig. 2). 8. Pull up on mechanism bracket. **and remove the locker slide only if broken, if the locker slide is not broken then skip to step 10). 9. Hold appropriate (right or left) replacement locker slide from kit p/n 05174865AA, and insert into mechanism bracket.** Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7201 10. Make sure main lever is in the correct position, (Fig. 3). If the main lever is in the up position before the pin/block, (Fig. 4), it means the module is mistimed (symptoms for this are that the module will go to vent, but will not open). 11. If the sunroof is mistimed, move the sunroof to the closed position and carefully move the mechanism into the vent position (by using the switch), guiding the main lever so the pin/block goes into the slot/track of the main lever. 12. Push the locker slide all the way back in the mechanism bracket. 13. Align the main lever, bushing and locker slide, (Fig. 5), by pushing down on the bracket and pulling forward on the main lever. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Track: > 23-049-04A > Dec > 04 > Body - Sunroof Vents Only/Won't Open or Close > Page 7202 14. Gently install the pin from the inside of the opening. Push the pin in with punch until the pin is flush with the face of the locker slide side of the mechanism bracket opening (outboard side). **If the pin or bushing become lost or damaged replacements are available in kit p/n 05174865AA. 15. Repeat steps 6 - 14 for the other side if necessary. 16. Make sure the locker slides are engaged and cycle the sunroof to the close position, 17. Position the glass panel in the roof opening. 18. Start, but do not tighten, the glass attachment screws. ** 19. Using a business card as a guide, slide the card around the edge of glass panel to ensure panel is centered in the opening. 20. Position the front of the sunroof glass panel so that the corners are flush to 1.0 mm below the top surface of the roof panel. 21. Position the rear of the sunroof glass panel so that the corners are flush to 1.0 mm over flush to the top surface of the roof panel. 22. With the aid of a helper, hold the glass panel in position and tighten glass attaching screws. 23. Cycle the sunroof and verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures Sunroof / Moonroof Windguard: Procedures WIND DEFLECTOR REMOVAL 1. Open sunroof to full open position. Fig. 1 Sunroof Components 2. Pull one end of wind deflector flap out of the wind deflector. 3. Release corner piece locking tab and separate corner piece from wind deflector beam. 4. Rotate corner piece outboard to release tab from roof flange. 5. Rotate corner piece to a vertical position and pull it up through hole in the sunshade guide. 6. Repeat for other corner piece. INSTALLATION 1. Hold corner piece vertically and push tab down through hole in the sunshade guide. 2. Rotate corner piece inward and place tab under roof flange. 3. Connect corner piece to wind deflector. 4. Install wind deflector flap into wind deflector. 5. Repeat for other corner piece. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures > Page 7207 Sunroof / Moonroof Windguard: Removal and Replacement WIND DEFLECTOR REMOVAL 1. Open sunroof to full open position. Fig. 1 2. Pull one end of wind deflector flap out of the wind deflector (Fig. 1). 3. Release corner piece locking tab and separate corner piece from wind deflector beam. 4. Rotate corner piece outboard to release tab from roof flange. 5. Rotate corner piece to a vertical position and pull it up through hole in the sunshade guide. 6. Repeat for other corner piece. INSTALLATION 1. Hold corner piece vertically and push tab down through hole in the sunshade guide. 2. Rotate corner piece inward and place tab under roof flange. 3. Connect corner piece to wind deflector. 4. Install wind deflector flap into wind deflector. 5. Repeat for other corner piece. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair Sunroof / Moonroof Interior Trim Panel: Service and Repair SUNSHADE REMOVAL 1. Open sunroof glass panel to the vent position. Fig. 1 2. Through the glass panel opening, disengage the two rear slide blocks of sunshade from sunshade guide (Fig. 1). 3. Slide the sunshade rearward to have access to the two front slide blocks of sunshade and disengage sunshade from sunshade guide. 4. Lift sunshade out of sunshade guide. INSTALLATION 1. Place sunshade with cloth side down and install one side's slide blocks into the track on the sunshade guide. 2. Slide the other side's slide blocks to fully inward position and insert them into the sunshade guide. 3. Verify that all four slide blocks are fully engaged in the sunshade guide. 4. Slide sunshade fully rearward and forward to verify operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Control Module Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module Sunroof / Moonroof Module: Service and Repair Sunroof Module REMOVAL Fig. 1 Sunroof Components 1. Remove sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Disengage front door weatherstrip from headliner, pull headliner down to access control unit. 2. Disconnect wire connector from control unit. 3. Slide control unit up and forward and remove. INSTALLATION 1. Place sunroof control unit into position. 2. Lock control unit into position. 3. Connect wire connector to control unit. 4. Install sun visors, front grab handles, A-pillar screw, Right upper B-pillar trim. Engage front door weatherstrip to headliner. 5. Cycle sunroof to the full open position. 6. Ensure sunroof adjustment. Refer to Sunroof Glass Adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 7216 Sunroof / Moonroof Module: Service and Repair Sunroof Module Assembly REMOVAL 1. Close glass panel, if possible 2. Remove A-pillar trim. 3. Remove upper B-pillar and C-pillar trim. Fig. 1 Sunroof Components 4. Remove sunroof welt. 5. Remove the switch. 6. Detach fastener from headlinder bracket to the front beam. 7. Remove all assist handles. 8. Remove sun visors. 9. Remove headlining and disconnect the dome lamp connector. 10. Disconnect sunroof motor wiring connector. 11. Disconnect drain tubes. 12. Remove fasteners attaching sunroof module to vehicle roof. 13. With the aid of a helper, remove sunroof module from roof. 14. Remove sunroof module from vehicle. INSTALLATION 1. With the aid of a helper, position sunroof module in vehicle. 2. Install fasteners attaching sunroof module to vehicle roof and support braces. Tighten all fasteners to 5 Nm (44 in. lbs.), starting from the front and working rearward and then the motor bracket. 3. Connect drain tubes. 4. Connect sunroof motor wiring connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 7217 5. Headliner in position connect dome lamp wire connector. Install headlining. 6. Install the fastener from the headliner bracket to front beam. 7. Install switch. 8. Install sunroof welt. 9. Install B-pillar and C-pillar trim. 10. Install A-pillar trim. 11. Install sun visors. 12. Install all assist handles. 13. Install sunroof sunshade. 14. Install sunroof glass panel. 15. Cycle glass panel open and close. 16. Ensure glass adjustment, refer to Glass Adjustment procedure 17. Verify correct operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Glass Sunroof / Moonroof Panel: Adjustments Sunroof Glass ADJUSTMENTS - SUNROOF GLASS FLUSHNESS 1. Position sunshade in full rearward position. Place the glass panel in the full closed position. 2. To adjust front of glass; a. Loosen front and middle glass attachment screws. b. Adjust front of sunroof glass panel so that the corners are flush to 1.0 mm below the top surface of the roof panel. c. Tighten all glass attachment screws. 3. To adjust rear of glass; a. Loosen rear and middle glass attachment screws. b. Adjust rear of sunroof glass panel so that the corners are flush to plus 1.0 mm off the top surface of the roof panel. c. Tighten all glass attachment screws. CENTERING SUNROOF GLASS ADJUSTMENT Fig. 5 Using a business card, check sunroof glass for center in opening (Fig. 5). Move business card around the glass seal, noting area where there is less pressure on the card. Loosen glass attaching screws adjust as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Glass > Page 7222 Sunroof / Moonroof Panel: Adjustments Sunroof Vent Position PLACING SUNROOF GLASS IN VENT POSITION 1. Remove the drive motor. 2. Remove sunroof glass panel. Fig. 2 Position Mechanism Slide 3. Slide the mechanism forward till the mechanism slide is parallel with the front edge of the guide. Fig. 3 Measuring Height - Out Of Vehicle Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Glass > Page 7223 Fig. 4 Measuring Height - In Vehicle 4. Using a rule, measure the rear end of the mechanism to the guide on each side of sun roof. 5. Initial height should be 44 - 48 mm. Adjust mechanism so that both sides are ± 1.0 mm of each other. 6. Install drive motor. 7. Install sunroof panel. 8. Ensure glass adjustment, refer to Glass Adjustment procedure. RE-POSITIONING DRIVE MOTOR If the drive motor is not in the correct position it can be adjusted to the correct position when the sunroof glass is in the vent position. Remove the drive motor from the sunroof module, reconnect the wires to the motor and press the motor switch to the vent position. This should place the drive motor into the vent position. The motor may now be installed if the sunroof glass panel is in the vent position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures Sunroof / Moonroof Panel: Procedures GLASS PANEL REMOVAL Fig. 1 Sunroof Components 1. Position sunroof sunshade in full rearward position. 2. Position the glass reinforcement panel in the CLOSED position before removing the six mounting screws. 3. Remove sunroof glass panel six screws. 4. Push glass panel upward from underside until glass panel clears the roof panel. 5. Lift glass panel from vehicle. INSTALLATION 1. Position glass reinforcement panel in roof opening. 2. Start, but do not tighten, glass attachment screws. Ensure glass is in the CLOSED position. 3. Cycle sunroof glass panel to the close position. Using a business card as a guide, slide card around the edge of glass panel to ensure panel is centered in opening. 4. With the aid of a helper, hold the glass panel in position and tighten glass attaching screws. 5. Ensure glass adjustment, refer to Glass Adjustment procedure. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures > Page 7226 Sunroof / Moonroof Panel: Removal and Replacement GLASS PANEL REMOVAL Fig. 1 1. Position sunroof sunshade in full rearward position (Fig. 1). 2. Position the glass reinforcement panel in the CLOSED position before removing the six mounting screws. 3. Remove sunroof glass panel six screws. 4. Push glass panel upward from underside until glass panel clears the roof panel. 5. Lift glass panel from vehicle. INSTALLATION 1. Position glass reinforcement panel in roof opening. 2. Start, but do not tighten, glass attachment screws. Ensure glass is in the CLOSED position. 3. Cycle sunroof glass panel to the close position. Using a business card as a guide, slide card around the edge of glass panel to ensure panel is centered in opening. 4. With the aid of a helper, hold the glass panel in position and tighten glass attaching screws. 5. Ensure glass adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Power Seat Motor (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 7238 Right Cylinder Lock Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7243 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH (EXPORT) REMOVAL 1. Open hood. Fig.1 Battery Negative Cable - Remove/Install 2. Disconnect and isolate the battery negative cable. 3. Disconnect wire harness connector from hood ajar switch. Fig.2 Hood Ajar Switch Location 4. Firmly press tangs on the bottom side of the switch together and push up through bracket. 5. Remove switch from vehicle. INSTALLATION 1. Firmly press hood ajar switch through bracket. 2. Connect wire harness connector to hood ajar switch. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Door (Driver) - LHD Door (Passenger) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7247 Door (Passenger) - RHD Fig. 61 Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7248 Fig. 62 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7249 Power Door Lock Switch: Diagrams Left Door Lock Switch Passenger Door Lock Motor/Ajar Switch Right Door Lock Switch Right Rear Door Lock Motor/Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7250 Power Door Lock Switch: Testing and Inspection 1. Remove the switch from its mounting location, and disconnect from vehicle wiring harness. (Refer to POWER LOCKS/POWER LOCK SWITCH - REMOVAL). Door Lock Switch Resistance 2. Using an ohmmeter, refer to the DOOR LOCK SWITCH RESISTANCE table to determine if switch resistance is correct in the Lock and Unlock switch positions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7251 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. RKE Module Location 3. Remove the two screws holding the RKE module to the instrument panel assembly. 4. Slide locking tab of the wiring connector sideways to unlock tab, and remove connector from RKE module. 5. Remove RKE module from vehicle. NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Additionally, all transmitters must be reprogrammed to the new RKE module. 1. Install the RKE module into the vehicle. 2. Connect the RKE wiring connector. 3. Install the two screws holding the RKE module to the instrument panel assembly. 4. Install the instrument panel top cover. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Door (Driver) - LHD Fig. 61 Door (Driver) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7255 Power Mirror Switch: Diagrams Power Mirror Switch (LHD) Power Mirror Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test Power Mirror Switch: Testing and Inspection Power Foldaway Mirror Switch Test The following test is designed to be used only on vehicles equipped with power fold-away side view mirrors. 1. Remove power mirror switch from mounting position (Refer to POWER MIRRORS/POWER FOLDAWAY MIRROR SWITCH - REMOVAL). Fig.2 Power Fold-Away Mirror Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the tables below. NOTE: When testing using the chart below be certain to read the chart correctly. Example - When testing left mirror "DOWN", pins 1, 9,10 will show continuity to each other, and pins 3, 4, 5 will show continuity to each other. 3. If test results are not obtained as shown in the tables below, replace the switch. Extended Mirror Switch Circuit Test Extended Mirror Switch Circuit Test NOTE: MIRROR POSITION SWITCH MUST BE IN THE "UNFOLD" POSITION TO USE CHART. Retracted Mirror Switch Circuit Test Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 7258 Retracted Mirror Switch Circuit Test NOTE: MIRROR POSITION SWITCH MUST BE IN THE "FOLD" POSITION TO USE CHART. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 7259 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove power mirror switch 2. Disconnect wiring harness connector from switch. Power Mirror Switch Table ( Part 1 Of 2 ) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Power Foldaway Mirror Switch Test > Page 7260 Power Mirror Switch Table ( Part 2 Of 2 ) 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 7261 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on window switch bezel and remove from door trim panel. 3. Disconnect wire connector from switch. 4. Remove two switch retaining screws. INSTALLATION 1. Install the retaining screws. 2. Reconnect the wire connector to the switch. 3. Insert switch into door trim panel 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Description and Operation Sunroof / Moonroof Limit Switch: Description and Operation LIMIT SWITCH DESCRIPTION The Sunroof Limit Switch is located in the drive motor assembly housing and is not serviceable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Sunroof Switch Sunroof Vent Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7274 Fig. 22 Instrument Panel Splices (Bottom Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7275 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7276 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7277 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7278 Fig. 35 Decklid - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7279 Decklid Release Switch (Power Release) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7280 Trunk / Liftgate Switch: Service and Repair DECKLID RELEASE SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry out on the deck lid release switch and pull out of instrument panel. 4. Disconnect the wiring connector. 5. Remove switch from vehicle. INSTALLATION 1. Connect the wiring connector. 2. Align switch in hole and firmly snap into place. 3. Close the glove box door. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair SPOILER REMOVAL 1. Remove the decklid cover. Refer to trim panel. Fig. 11 2. Remove the four nuts and remove the spoiler. (Fig. 11) INSTALLATION 1. Install the spoiler and nuts (Fig. 11). 2. Tighten nuts to 3 N.m (30 in.lbs.) torque. 3. Install the decklid cover. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE SCREEN REMOVAL 1. Release hood latch and open hood. 2. Remove windshield wiper arms. Fig. 1 3. Remove the five screws attaching cowl screen cover to just below windshield flange. (Fig. 1). 4. Remove cowl plenum to hood weatherstrip, at the leading edge of cowl cover. Pull weatherstrip towards the front of the vehicle to remove. 5. Remove cowl screen windshield seal from upper edge of the cowl screen cover. 6. Remove cowl screen cover from the vehicle. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 7290 Fig. 2 1. Place cowl screen cover into position on vehicle (Fig. 2). 2. Start five screws attaching cowl screen cover to cowl at base of windshield opening. 3. Install cowl screen windshield seal to upper edge of the cowl screen. 4. Push cowl plenum to hood weatherstrip, into position on the leading edge of cowl screen cover. 5. Install windshield wiper arms. 6. Tighten screws attaching cowl screen cover to cowl at base of windshield opening. 7. Install windshield wiper arms. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar Front Door Window Glass Weatherstrip: Service and Repair Front Vertical Guide Bar FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7296 Front Door Window Glass Weatherstrip: Service and Repair B-Pillar Weatherstrip Channel B-PILLAR WEATHERSTRIP CHANNEL REMOVAL 1. Remove b-pillar applique. 2. Remove push in fasteners attaching weatherstrip to b-pillar. 3. Pull weatherstrip from b-pillar channels. 4. Remove screws attaching channels to b-pillar. 5. Remove channels from b-pillar. INSTALLATION 1. Install channels from b-pillar. 2. Install screws attaching channels to b-pillar. 3. Install weatherstrip to b-pillar channels. 4. Install push in fasteners attaching weatherstrip to b-pillar. 5. Install b-pillar applique. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7297 Front Door Window Glass Weatherstrip: Service and Repair FDR Glass Run Weatherstrip FDR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove flag cover, door trim panel, water dam as necessary. 2. Remove door glass. 3. Loosen side view mirror, as necessary. 4. Remove weatherstrip fasteners. 5. Pull weatherstrip from lower front channel above door latch. Fig. 1 6. Pull run weatherstrip from window frame channel (Fig. 1). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Tighten side view mirror. 8. Install pull cup support bracket, water shield, door trim panel and flag trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7298 Front Door Window Glass Weatherstrip: Service and Repair Outer Belt Weatherstrip OUTER BELT WEATHERSTRIP REMOVAL 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Fig. 2 3. Remove outer belt weatherstrip from vehicle (Fig. 2). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7299 Front Door Window Glass Weatherstrip: Service and Repair Front Vertical Guide Bar FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. B-Pillar Weatherstrip Channel B-PILLAR WEATHERSTRIP CHANNEL REMOVAL 1. Remove b-pillar applique. 2. Remove push in fasteners attaching weatherstrip to b-pillar. 3. Pull weatherstrip from b-pillar channels. 4. Remove screws attaching channels to b-pillar. 5. Remove channels from b-pillar. INSTALLATION 1. Install channels from b-pillar. 2. Install screws attaching channels to b-pillar. 3. Install weatherstrip to b-pillar channels. 4. Install push in fasteners attaching weatherstrip to b-pillar. 5. Install b-pillar applique. FDR Glass Run Weatherstrip FDR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove flag cover, door trim panel, water dam as necessary. 2. Remove door glass. 3. Loosen side view mirror, as necessary. 4. Remove weatherstrip fasteners. 5. Pull weatherstrip from lower front channel above door latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7300 Fig. 1 6. Pull run weatherstrip from window frame channel (Fig. 1). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Tighten side view mirror. 8. Install pull cup support bracket, water shield, door trim panel and flag trim. Outer Belt Weatherstrip OUTER BELT WEATHERSTRIP REMOVAL 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7301 Fig. 2 3. Remove outer belt weatherstrip from vehicle (Fig. 2). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Door Upper Secondary Weatherstrip DOOR UPPER SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7302 Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7307 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door trim panel, water dam as necessary. 2. Remove door glass. 3. Remove weatherstrip fasteners. 4. Pull weatherstrip from lower front channel above door latch. Fig. 4 5. Pull run weatherstrip from window frame channel (Fig. 4). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Install pull cup support bracket, water shield, and door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7308 Rear Door Window Glass Weatherstrip: Service and Repair RDR Secondary Weatherstrip RDR SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool C-4829 or equivalent, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7309 Rear Door Window Glass Weatherstrip: Service and Repair Roof Rail Weatherstrip ROOF RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. 2. Using a door trim removing tool, disengage the push-in fasteners holding A-pillar and C-pillar weatherstrip molding. 3. Starting at the bottom of the A-pillar, pull the roof rail weatherstrip from the windshield side molding. Fig. 5 4. Pull roof rail weatherstrip from the roof rail pinch flange above the door opening (Fig. 5). 5. Separate roof rail weatherstrip from vehicle. INSTALLATION 1. Place weatherstrip in position on pinch flange. 2. Starting at the bottom of the C-pillar, install the roof rail weatherstrip molding to the pinch rail. 3. Install push-in fasteners to hold weatherstrip to A-pillar and C-pillar. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7310 Rear Door Window Glass Weatherstrip: Service and Repair Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door trim panel, water dam as necessary. 2. Remove door glass. 3. Remove weatherstrip fasteners. 4. Pull weatherstrip from lower front channel above door latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7311 Fig. 4 5. Pull run weatherstrip from window frame channel (Fig. 4). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Install pull cup support bracket, water shield, and door trim panel. RDR Secondary Weatherstrip RDR SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool C-4829 or equivalent, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Roof Rail Weatherstrip ROOF RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. 2. Using a door trim removing tool, disengage the push-in fasteners holding A-pillar and C-pillar weatherstrip molding. 3. Starting at the bottom of the A-pillar, pull the roof rail weatherstrip from the windshield side molding. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7312 Fig. 5 4. Pull roof rail weatherstrip from the roof rail pinch flange above the door opening (Fig. 5). 5. Separate roof rail weatherstrip from vehicle. INSTALLATION 1. Place weatherstrip in position on pinch flange. 2. Starting at the bottom of the C-pillar, install the roof rail weatherstrip molding to the pinch rail. 3. Install push-in fasteners to hold weatherstrip to A-pillar and C-pillar. Roof Rail Weatherstrip Retainer Channel ROOF RAIL WEATHERSTRIP RETAINER CHANNEL REMOVAL 1. Open door(s). 2. Using trim stick disconnect 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, ensure all of the old two sided tape is removed from the vehicle surface before installation of new part. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7313 Fig. 6 3. Remove weatherstrip from the retainer channel (Fig. 6). 4. Remove retainer channel from the body side aperture. INSTALLATION 1. Install retainer channel to the body side aperture. 2. Remove weatherstrip from the retainer channel. 3. Connect the top and bottom push in fasteners to B-pillar applique. Gently push on the applique to install from the vehicle. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL Fig. 7 1. Using a fork-type prying tool, disengage push in fasteners attaching sill secondary weatherstrip to door (Fig. 7). 2. Remove weatherstrip from door. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7314 INSTALLATION 1. Position weatherstrip to door. 2. Press sill secondary weatherstrip fasteners into position. Trunk Opening Weatherstrip TRUNK OPENING WEATHERSTRIP REMOVAL 1. Open decklid. Fig. 8 2. Pull decklid weatherstrip form decklid opening fence (Fig. 8). 3. Remove weatherstrip from vehicle. INSTALLATION 1. Place decklid opening weatherstrip into position. 2. Press the weatherstrip onto the decklid opening fence. 3. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations 2.0L Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 7325 Speed Control Servo Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 7326 Cruise Control Servo: Description and Operation SPEED CONTROL SERVO The servo unit consists of a solenoid valve body, and a vacuum chamber The solenoid valve body contains three solenoids Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage 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 Power is supplied to the servo by the PCM through the brake switch The PCM controls the ground path for the vacuum and vent solenoids The dump solenoid is energized anytime it receives power If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo This provides a safety backup to the vent and vacuum solenoids The vacuum and vent solenoids must be grounded by the PCM to operate When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo The PCM also operates the vent solenoid via ground The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required The PCM cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle To increase throttle opening, the PCM grounds the vacuum and vent solenoids To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 7327 Cruise Control Servo: Service and Repair SPEED CONTROL SERVO REMOVAL Fig.6 Speed Control Servo 1. Disconnect electrical connector from servo. 2. Disconnect vacuum hose from servo. 3. Remove 2 nuts retaining bracket to servo. 4. Remove cable bell housing from servo mounting studs. 5. Remove retaining clip pin holding cable to servo. INSTALLATION 1. Install retaining clip to cable at servo 2. Install 2 nuts at cable to servo and servo bracket, tighten to 7 Nm (60 in. lbs.). 3. Connect electrical connector to servo. 4. Connect vacuum hose to servo. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations Cruise Control Servo Cable: Locations The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7331 Cruise Control Servo Cable: Description and Operation SPEED CONTROL SERVO CABLE 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7332 Cruise Control Servo Cable: Service and Repair SPEED CONTROL SERVO CABLE REMOVAL 1. Disconnect the negative battery cable 2. Remove the throttle cable cover Fig.3 Disconnecting Throttle Cable 3. Remove speed control cable from throttle lever by sliding clasp out of the hole. 4. Lift the retaining tab on the throttle cable and slide cable out of bracket Lift the retaining tab on the speed control cable and slide cable out of bracket 5. Disconnect electrical connector from servo 6. Disconnect vacuum hose from servo. Fig.4 Speed Control Servo 7. Remove 2 nuts retaining bracket to servo. 8. Remove push nuts holding cable housing to Servo. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7333 Fig.5 Speed Control Cable 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 Nm (60 in. lbs.) 5. Connect electrical connector to servo 6. Connect vacuum hose to servo 7. Rotate the throttle lever forward to the wide open position and install speed control cable clasp. 8. Slide speed control cable into throttle cable bracket and engage retaining tab Slide throttle cable into throttle cable bracket and engage retaining tab. 9. Install the Throttle cable cover. 10. Connect the negative battery cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7337 Cruise Control Switch: Service Precautions WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7338 Cruise Control Switch: Description and Operation SPEED CONTROL SWITCHES The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM The switch names are ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, COAST, and CANCEL Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, TAP-DOWN, COAST, and CANCEL Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed The individual switches cannot be repaired If one switch fails, the entire switch module must be replaced Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7339 Cruise Control Switch: Service and Repair SPEED CONTROL SWITCHES The speed control switch is mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS. Fig.7 Speed Control Switch REMOVAL 1. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 2. Remove the negative battery cable. 3. Turn off ignition. 4. Remove air bag, refer to the Restraint systems section. Fig.8 Switch Top Mounting Screw 5. Remove the top mounting screw. 6. Rotate steering wheel so that the switch is in the 6 o'clock position. Remove 2 screws from the back side of the speed control switch. 7. Disconnect the electrical connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7340 Fig.9 Switch Removal 8. Remove switch. INSTALLATION 1. Connect the electrical connector. 2. Install switch and tighten the screws to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch. 3. Install airbag, refer to the Restraint Systems section. 4. Install the negative battery cable. 5. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations Cruise Control Vacuum Reservoir: Locations The vacuum reservoir is located in the engine compartment It is made of plastic. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 7344 Cruise Control Vacuum Reservoir: Description and Operation VACUUM RESERVOIR The vacuum reservoir is located in the engine compartment. It is made of plastic. The reservoir stores engine vacuum. Manifold vacuum is supplied from the brake booster check valve. The speed control vacuum supply hose has a check valve at the source (brake booster) to maintain the highest available vacuum level in the servo, reservoir and vacuum hoses. 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 7345 Cruise Control Vacuum Reservoir: Service and Repair VACUUM RESERVOIR REMOVAL 1. Remove the passenger side cowl screen.. Fig.10 Vacuum Reservoir Mounting 2. Remove vacuum reservoir mounting nuts. Fig.11 Vacuum Reservoir Connections 3. Remove vacuum hose and throttle cable tie strap push clip. 4. Remove vacuum reservoir. INSTALLATION 1. Install vacuum reservoir, install nuts and tighten to 4.5 Nm (40 in. lbs.). 2. Install vacuum hose. 3. Install the throttle cable push clip onto reservoir. NOTE: Throttle cable must be clipped to the reservoir to prevent contact with the exhaust manifold. 4. Install the passenger side cowl screen. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7356 Cruise Control Switch: Service Precautions WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7357 Cruise Control Switch: Description and Operation SPEED CONTROL SWITCHES The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM The switch names are ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, COAST, and CANCEL Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, TAP-DOWN, COAST, and CANCEL Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed The individual switches cannot be repaired If one switch fails, the entire switch module must be replaced Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7358 Cruise Control Switch: Service and Repair SPEED CONTROL SWITCHES The speed control switch is mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS. Fig.7 Speed Control Switch REMOVAL 1. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 2. Remove the negative battery cable. 3. Turn off ignition. 4. Remove air bag, refer to the Restraint systems section. Fig.8 Switch Top Mounting Screw 5. Remove the top mounting screw. 6. Rotate steering wheel so that the switch is in the 6 o'clock position. Remove 2 screws from the back side of the speed control switch. 7. Disconnect the electrical connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7359 Fig.9 Switch Removal 8. Remove switch. INSTALLATION 1. Connect the electrical connector. 2. Install switch and tighten the screws to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch. 3. Install airbag, refer to the Restraint Systems section. 4. Install the negative battery cable. 5. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations ABS Light: Locations The amber ABS warning indicator lamp is located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 7364 ABS Light: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application ABS Indicator ....................................................................................................................................... ................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 7365 ABS Light: Description and Operation ABS WARNING INDICATOR The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off due to a system malfunction. The CAB controls the lamp indirectly. The CAB monitors its own functions. If the CAB determines that the ABS warning indicator should be on, the CAB sends a message via the PCI BUS to the instrument cluster and the cluster turns on the indicator. The indicator will remain lit during every key cycle until the circuit or component fault is repaired and the CAB no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TRAC OFF Indicators. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB. When the ignition key is turned to the ON position, the amber ABS warning indicator lamp is lit until the Controller Antilock Brake (CAB) completes its self-tests and turns OFF the lamp (approximately 4 seconds). The amber ABS warning indicator lamp will illuminate when the CAB detects a condition that results in the shutdown of ABS function. The CAB sends a message to the Mechanical Instrument Cluster (MIC) instructing it to turn ON the amber ABS warning indicator lamp. Under most conditions, when the amber ABS warning indicator lamp is ON, only the ABS function of the brake system is affected; The Electronic Brake Distribution (EBD), the base brake system and the ability to stop the vehicle are not affected. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Audible Warning Device: Locations The Chime Module is located within the instrument cluster and is not serviceable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations > Page 7369 Audible Warning Device: Description and Operation CHIME/BUZZER The Chime Module is located within the instrument cluster and is not serviceable. The chime/buzzer system provides the driver with warning chimes for: Seat Belt - Exterior Lamps ON - Key-In Ignition - Warning Lamp Announcement - Turn Signal ON - Park Brake - Low Fuel Fasten Seat Belt The seat belt reminder system uses both visual and audible signals. A combined seat belt and key reminder chime with a red light on the instrument panel. The system will illuminate the seat belt reminder lamp for when the ignition switch is turned to the ON position. The CHIME will sound 4 - 8 seconds if the driver's seat belt is not fastened. Passenger belts are not connected to the system. The light will stay illuminated at all times when the driver seat belt is not buckled. Headlamps Reminder These are the conditions that have to be met for the headlamps ON, chime function to work: Headlamps ON and - Driver's door open and - Key removed from the ignition switch. Chime should sound until headlamps are turned OFF or the drivers door is closed. Key In Ignition Reminder The chime will activate if the drivers door is opened and the key is in the ignition switch, with the ignition switch in either the OFF, LOCK, or the accessory (ACC) position. Door Ajar Chime The chime will sound once when: Door opened and - Ignition in RUN position and - Vehicle speed is present Turn Signal ON The cluster shall remind the driver that either turn signal has been left ON by continuously chiming after: Left or Right turn signal left ON for 1.0 mile and - Vehicle speed of 15 mph or greater. Park Brake Reminder The cluster shall chime 10 times and continuously flash the brake indicator when: Park brake is activated and - Vehicle speed is present. Low Fuel Reminder When the fuel level drops to about 1/8 tank, the fuel symbol will light and a single chime will sound. The light will remain ON until fuel is added. If the fuel level drops to about 1/16 of a tank, the fuel symbol will flash several times and the chime will sound several times. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations > Page 7370 Audible Warning Device: Testing and Inspection CHIME SYSTEM CONDITIONS No Tone When Ignition Switch Is Turned ON And Drivers Seat Belt Is Unbuckled 1. Using an ohmmeter, with the seat belt fully retracted, check for continuity to ground at Pin 20 of the 26-way cluster harness connector. If OK, go to Step 2. If not OK, repair as necessary. 2. Using voltmeter, check for battery feed at Pin 4 of the 26-way cluster harness connector. Check for ignition feed at Pin 14 of the 26-way cluster harness connector. If not OK, repair as necessary. No Fasten Seat Belt Lamp When Ignition Switch Is ON 1. Check for battery feed at cluster harness connector Pin 4. 2. Check for ignition feed at cluster harness connector Pin 14. Repair as necessary. No Tone When Headlamps are ON And Drivers Door Is Open 1. Remove the key from the ignition. 2. Check left door jamb switch for good ground when drivers door is open. 3. Check for ground at Pin 1 of the 26-way cluster harness connector. 4. Check for battery feed at cluster harness connector Pin 4 of the 26-way cluster harness connector. 5. Check for NO voltage at Pin 14. Ignition voltage must not be present for the chime to work. 6. Check headlamp switch. No Tone When Key Is Left In Ignition And Drivers Door Is Open 1. Check for continuity to ground at Pin 1 of the 26-way cluster harness connector. If OK, go to Step 3. If not OK, repair as necessary 2. Using voltmeter, check for battery feed at Pin 21 of the 26-way cluster harness connector. Check for NO ignition feed at Pin 14 of the 26-way cluster harness connector. If OK, go to Step 3. If not OK, repair as necessary. 3. Open driver's door and ensure the ignition key is in the OFF, LOCK, or ACC position. Check for continuity to ground at Pin 9 of the 26-way cluster harness connector. If ground OK, replace cluster printed circuit board. If no ground, check key-in switch or door switch wiring and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Brake System Warning Indicator ......................................................................................................... .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions > Page 7374 Brake Warning Indicator: Testing and Inspection BRAKE/PARK BRAKE INDICATOR 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 To test the service brake warning system, refer to Brakes, Hydraulic System Control Valves. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Fig. 12 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS 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. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 Circuit Identification Code Chart 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 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 Wire 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. Connector Views Information Connector views show the connector and the circuits associated with that connector. The connectors are identified using the name/number on the diagram sheets. A master list can be found at Vehicle / Diagrams. See: Diagrams/Connector Views Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 - In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 - 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. Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 Fig. 17 Heat Shrink Tube 6. 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 (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety elsewhere in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle / Diagrams / Electrical / Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Symbols Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 Cigar Lighter/Power Outlet Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7405 Cigarette Lighter: Service and Repair CIGAR LIGHTER OUTLET REMOVAL 1. Disconnect and isolate the battery negative cable Fig. 1 Cigar Lighter/Power Outlet Base Removal 2. Look inside and note position of the retaining bosses (Fig. 1). 3. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. Fig. 2 Cigar Lighter/Power Outlet Base Removal 4. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the same (Fig. 2). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7406 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location 3. Push base into the bezel till it locks. 4. Install cigar lighter cap and check operation of element. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Compass: Locations The compass is located within the mirror module and can not be serviced separately. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7410 Compass/Temperature Mirror Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7411 Compass: Description and Operation COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7412 Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7413 the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Compass/Mini-Trip Computer (CMTC) Self-Diagnostics Compass: Testing and Inspection Compass/Mini-Trip Computer (CMTC) Self-Diagnostics COMPASS/TEMPERATURE MIRROR TEST If the Compass/Temperature mirror lights up and functions, however the accuracy of the information displayed is in question or certain displays are not working, refer to the self-diagnostic test below. If the mirror doesn't light up or function, proceed with the following preliminary tests: 1. Disconnect the compass/temperature mirror electrical connector. Using a voltmeter, check for 12v on the fused B+ circuit cavity. Voltage should be present. If OK go to Step 2, If NOT OK, repair the short or open circuit as required. 2. Using a voltmeter, check for 12v on the fused ignition run circuit cavity with the ignition switch in the RUN position. Voltage should be present. If OK go to Step 3, If NOT OK, repair the short or open circuit as required. 3. Key OFF. Using a ohmmeter, check for continuity to a good ground on the ground circuit cavities of the compass/temperature mirror electrical connector. Continuity should be present. If OK, replace the mirror assembly, If NOT OK, repair the short or open circuits as required. Compass/Temperature Mirror Self-Diagnostic Test NOTE: If the ignition switch is turned OFF during any period of the self diagnostic procedure, the mirror will exit the self diagnostic mode. - Pressing and releasing the zone/calibration button will exit the self diagnostic mode and return to the standard compass/temperature mode To perform the Compass/Temperature Mirror Self-Diagnostic routine: 1. Turn the ignition to the ON position. 2. Press and hold the zone/calibration (left reading lamp button) button for 20 - 25 seconds. 3. During testing, if any of the test fail, a "F" will appear. If more than one test fail, "FO" will appear. If "F" or FO" appear, replace the compass /temperature mirror. 4. If a "P" is displayed, that indicates that the compass/temperature mirror has passed the self diagnostic procedure. NOTE: If, after performing the self diagnostic procedure the compass still has an incorrect reading, perform the compass calibration or compass variation adjustment. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Compass/Mini-Trip Computer (CMTC) Self-Diagnostics > Page 7416 Compass: Testing and Inspection Self-Check Diagnostics SELF-CHECK DIAGNOSTICS With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20 - 25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display - Illuminates the segment patterns one at a time for 1 second each as follows: - CAL - ZONE -N - NE -E - SE -S - SW -W - NW - 0 through 9 - degrees C - degrees F 2. CTM memory - ROM Checksum 3. CTM memory - RAM 4. CTM memory - EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Compass/Mini-Trip Computer (CMTC) Self-Diagnostics > Page 7417 Compass: Testing and Inspection Ambient Temperature Sensor Diagnostics AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass /Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Compass: Service and Repair Compass Calibration Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15-20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature F degrees, or Compass/Temperature C degrees. Pressing and holding the Zone/Cal button for 20-25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10-15 seconds will toggle the display to CAL. Releasing the button within the 10-15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 7420 Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 degrees F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 degrees C (140 degrees F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 degrees C (140 degrees F) to indicate a short circuit condition. If the measured outside temperature is less than -45 degrees C (-49 degrees F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 degrees C (-49 degrees F) to indicate an open circuit condition. Ambient Temperature Sensor On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the compass/temp module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 degrees C (140 degrees F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 degrees C (140 degrees F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 degrees C (-49 degrees F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 degrees C (-49 degrees F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: - 0 degrees C (32 degrees F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10 degrees C (50 degrees F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20 degrees C (68 degrees F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25 degrees C (77 degrees F) Sensor Resistance = 9.12 - 10.86 Kilohms - 30 degrees C (86 degrees F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40 degrees C (104 degrees F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 7421 Compass: Service and Repair Compass Variation Adjustment STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. ZONE METHOD Fig.2 Variance Settings 1. Using the Variance Settings map, find your geographic location and note the zone number (Fig. 2). 2. Turn the ignition switch to the ON position. Press and hold the Zone/Calibration (left reading lamp button) button for 5 - 10 seconds. The Zone symbol should be illuminated. 3. Releasing the Zone /Calibration button while the ZONE symbol is illuminated will cause the mirror to enter the zone display mode. 4. The current variance zone will now be displayed. To change the zone, press the Zone/Calibration button until the correct zone is displayed. Wait for 5 seconds. 5. After 5 seconds, the displayed zone will automatically be set in the mirror memory and normal operation will resume. 6. Confirm that the correct directions are now indicated by the compass. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7426 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7430 Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7431 Fig. 23 Door (Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7432 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7433 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7434 Fig. 44 Body (Right Rear) - RHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7435 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7436 Door Switch: Diagrams Driver Door Ajar Switch Hood Ajar Switch (Export) Left Rear Door Ajar Switch Passenger Door Ajar Switch Right Rear Door Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fog/Driving Lamp Indicator > Component Information > Application and ID Fog/Driving Lamp Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Front Fog Lamp Indicator .................................................................................................................... .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7443 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor (track). The resistor track is used to send electrical signals to the instrument cluster for fuel gauge operation and are then transmitted to the engine controller for OBDII emission requirements. For Fuel Gauge Operation: As fuel level increases, the float and arm move up. This increases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This decreases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the instrument cluster, the instrument cluster will transmit the data across the J1850 bus circuits to the PCM. For OBD II Emission Requirements: The voltage signal is sent to the instrument cluster to indicate fuel level. The cluster transmits the fuel level to the PCM where it is used to prevent a false setting of misfire and fuel system monitor trouble codes. This occurs if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7444 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDING UNIT/SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig.4 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 4). Fig.5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge (Fig. 5). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7445 Fig.6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 6). 4. Push level sensor signal and ground terminals out of the connector (Fig. 6). Fig.7 Level Sensor 5. Slide level sensor wires through opening fuel pump module (Fig. 7). 6. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 7). Ensure tab at bottom of sensor locks in place. 4. 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. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7450 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Service and Repair Map Lamp: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small thin blade tool, pry at the center of the lens nearest the mirror to remove lens. 3. Remove cartridge lamp. INSTALLATION 1. Install lens by setting lens into position and applying pressure until it is locked into position. 2. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Application and ID Low Fuel Lamp/Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Low Fuel Indicator ............................................................................................................................... ................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Malfunction Indicator Light ................................................................................................................... ............................................................... LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Application and ID > Page 7461 Malfunction Indicator Lamp: Description and Operation Refer to the Instrument Cluster for more information. The PCM supplies the malfunction indicator (check engine) lamp ON/OFF signal to the instrument panel through the PCI Bus. The PCI Bus is a communications port. Various modules use the PCI Bus to exchange information. The Check Engine lamp comes ON each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Malfunction Indicator Lamp (MIL) stays ON continuously when the PCM has entered a Limp-In mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM compensates for the failure of certain components that send incorrect signals. The PCM substitutes for the incorrect signals with inputs from other sensors. If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the MIL. At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger the MIL (Check Engine Lamp) refer to the On-Board Diagnostics. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Application and ID Oil Change Reminder Lamp: Application and ID This vehicle did not have an Oil Change Reminder Light. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation OIL PRESSURE SENSOR/ SWITCH DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 120). The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). OPERATION The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig of the switch's "Closed" circuit pressure point. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Description and Operation > Page 7468 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle. 2. Position oil collecting container under pressure switch location. 3. Disconnect oil pressure switch electrical connector and remove switch (Fig. 121). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 121). 2. Lower vehicle. 3. Start engine and allow to run a minimum of 2 minutes. 4. Shut engine off and check engine oil level. Adjust level as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Low Oil Pressure Indicator .................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID > Page 7472 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The low oil pressure indicator 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. Fig.2 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 (Fig. 2). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation Outside Temperature Display: Description and Operation COMPASS/TEMPERATURE MIRROR The optional Compass/Temperature Mirror has a vacuum fluorescent (VF) display that is integrated into the rear view mirror. The Compass/Temp Mirror includes the compass/temperature display and two map/reading lamps. This display provides the outside temperature and one of eight compass headings to indicate the direction the vehicle is facing. The Compass/Temp Mirror displays the compass heading and the outside temperature at the same time. The Ambient Temperature Sensor monitors the outside temperature and is hardwired to the Compass/Temp Mirror (1.6L vehicles), or is hard-wired to the PCM (2.0L vehicles). The Compass/Temp Mirror also receives and transmits data on the PCI Bus. The Compass/Temp Mirror incorporates 2 reading lamp buttons with the STEP button and the Zone/Calibration button features activated by holding a button for a specified time period. The STEP button provides the selections between English and Metric. The Zone/Cal button provides the selection to change the compass zone or to calibrate the compass. The reading lamp buttons also cycle the reading lamps on or off. The STEP button (right reading lamp button) operates a momentary contact switch which provides input to the Compass/Temp Mirror in one of the following four modes: - To toggle the right reading lamp on and off upon release of the button. - To select degrees in F (Fahrenheit) for the temperature display. - To select degrees in C (Celsius) for the temperature display. - To turn off the compass/temperature display. English/Metric/Off Mode With the ignition in the ON position, pressing and holding the STEP button (right reading lamp button) for 5-10 seconds will toggle the display between English and Metric. The Compass/Temp Mirror stores the selected display mode in memory upon releasing the button during the 5-10 seconds. Pressing and holding the STEP button for 10-15 seconds will turn the display OFF upon releasing the button during the 10-15 seconds. Each time the temperature mode is changed to F degrees or C degrees, the Compass/Temp Mirror stores the new mode in memory. The selected English or Metric mode is recalled after the ignition is cycled. The display OFF mode is not recalled after the ignition is cycled. The Compass/Temp Mirror will power up and display the temperature mode (F degrees or C degrees) that was last selected. COMPASS Calibration/Zone Mode Refer to the Zone Variance Map. With the ignition in the ON position, pressing and holding the Zone/ Cal button (left reading lamp button) for 5-10 seconds will illuminate ZONE in the display. Releasing the button while ZONE is illuminated will enter the compass into the Zone Setting mode. The Compass/Temp Mirror will illuminate the Zone Variance number 1 to 15 that is stored in memory. While ZONE is displayed; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds, the Zone Variance number will be stored in the module memory. With the ignition in the ON position, pressing and holding the Zone/Cal button for 10-15 seconds will toggle the CAL (calibration) mode between on and off. Releasing the button while CAL is displayed enters the compass into the calibration mode. See "First Time Calibration", "Manual Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation > Page 7476 Calibration", and "Continuous Calibration." Pressing and holding the Zone/Cal button for 15 - 20 seconds and then releasing will exit the CAL mode and toggle the display to the current state of compass/temperature mirror use; OFF, Compass/ Temperature °F, or Compass/Temperature °C. Pressing and holding the Zone/Cal button for 20 - 25 seconds will enter the CTM into the self-check diagnostic mode upon releasing the button. Holding the Zone/Cal button for longer than 25 seconds will cause the display to return to its current state with no changes. Setting Compass Zone The compass has a default zone of 8. Refer to the Zone Variance Map to determine the correct zone number. The correct compass Zone selection is critical to proper compass operation. With the ignition in the ON position, pressing the Zone/Cal button (left reading lamp button) for 5-10 seconds and then releasing while ZONE is illuminated enters the compass into the Zone display mode. In the Zone display mode, ZONE will be illuminated instead of the temperature. The current Zone number, 1 through 15 will be displayed. While ZONE is illuminated; momentarily pressing the Zone/Cal button advances the zone to the next higher zone. When the desired zone number is displayed, do not press the Zone/Cal button again. After 5 seconds , the Zone Variance number will be stored in the module memory. First Time Calibration A new Compass/Temp Mirror is shipped in a first time calibration mode. CAL is illuminated when the Compass/Temp Mirror is first powered up. The first time calibration mode can not be exited until the first time calibration process is completed. The CAL icon will remain illuminated to alert the driver that the Compass/Temp Mirror is operating in the CAL mode. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 mph (8 km/h). The compass will calibrate; CAL will turn off, and then resume normal operation. Manual Calibration With the ignition in the ON position, pressing and holding the Zone/Cal button (left reading lamp button) for 10 - 15 seconds will toggle the display to CAL. Releasing the button within the 10 - 15 second duration will enter the compass into the calibration mode. CAL will remain illuminated until the calibration is complete or is toggled off by pressing the Zone/Cal button. Move the vehicle to an area away from large metallic objects or overhead power lines. While CAL is illuminated in the display the vehicle must be driven in 3 complete 360 degree circles at less than 5 MPH (8 KPH). The compass will calibrate; CAL will turn off, and then resume normal operation. Continuous Calibration During normal operation, the Compass/Temp Mirror will continuously update the compass calibration to adjust for gradual changes in the vehicle's magnetic remnant field. If the vehicle is subjected to high magnetic influences, the compass may appear to indicate false headings or appear unable to be calibrated. If this occurs the vehicle may need to be demagnetized. Refer to Demagnetizing Procedure. Self-Check Diagnostics With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20-25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display-Illuminates the segment patterns one at a time for 1 second each as follows: CAL; ZONE; N; NE; E; SE; S; SW; W; NW; 0 through 9; C degrees; F degrees 2. CTM memory-ROM Checksum 3. CTM memory-RAM 4. CTM memory-EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. TEMPERATURE Outside Temperature The Compass/Temp Mirror utilizes vehicle speed and engine temperature data received on the PCI Bus to accurately display the outside temperature to avoid "hot soak" condition readings. The displayed outside temperature information is stored within the memory of the compass/temp mirror. When the Compass/Temp Mirror is first powered up, it retrieves the temperature data from the module memory. The memory temperature is compared with the temperature received from the ambient temperature sensor. The colder of the two temperatures is displayed. Temperature Update - Warm On power up, when the outside temperature sensed by the ambient temperature sensor is warmer than the temperature stored in the module memory, Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation > Page 7477 the Compass/Temp Mirror will update the displayed temperature in relation to vehicle speed and engine temperature data received on the PCI Bus. Temperature Update - Cold On power up, when the outside air temperature sensed by the ambient temperature sensor is colder than the stored memory temperature, the Compass/ Temp Mirror will update the displayed temperature to the outside temperature at a rate of -1 °F every 2 seconds, regardless if the vehicle is moving or not. Extreme temperature/Open or Short Condition If the measured outside temperature is more than 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a short circuit condition. If the measured outside temperature is less than -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 ° C (-49 °F) to indicate an open circuit condition. AMBIENT TEMPERATURE SENSOR On these equipped vehicles, the Ambient Temperature Sensor is hardwired to the PCM. The ambient air temperature is monitored and displayed by the Compass/Temp Mirror. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The resistance in the ambient temperature sensor changes as the outside temperature rises or falls. The PCM senses the change in reference voltage through the ambient temperature sensor resistor. Based on the resistance of the ambient temperature sensor, the PCM is programmed to correspond to a specific temperature. The Compass/Temp Mirror then displays the proper ambient temperature. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the Compass/Temp Module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 °C (140 °F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 °C (140 °F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 °C (-49 °F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 °C (-49 °F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: TEMPERATURE ............................................................................................................................................................. SENSOR RESISTANCE 0 °C (32 °F) ......................................................................................................................................... .................................... 29.33 - 35.99 Kilohms 10 °C (50 °F) .............................................................. ............................................................................................................. 17.99 - 21.81 Kilohms 20 °C (68 °F) ................................................................................................................................................. .......................... 11.37 - 13.61 Kilohms 25 °C (77 °F) ........................................................................ ..................................................................................................... 9.12 - 10.86 Kilohms 30 °C (86 °F) .............................................................................................................................................................. ................. 7.37 - 8.75 Kilohms 40 °C (104 °F) ................................................................................... .......................................................................................... 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Ground circuits. If the resistance values are not OK, replace the Sensor. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation > Page 7478 Outside Temperature Display: Testing and Inspection SELF-CHECK DIAGNOSTICS With the ignition ON, the Compass/Temp Mirror can perform a diagnostic self-check by pressing and holding the Zone/Cal button (left reading lamp button) for 20 - 25 seconds. The internal diagnostics will sequence the following five tests: 1. VF segment display - Illuminates the segment patterns one at a time for 1 second each as follows: - CAL - ZONE -N - NE -E - SE -S - SW -W - NW - 0 through 9 - degrees C - degrees F 2. CTM memory - ROM Checksum 3. CTM memory - RAM 4. CTM memory - EEPROM 5. Compass Test During the self-check, if any of the internal tests fail, the Compass/Temp Mirror will display an "F" and the number of the test that failed. If more than one test fails "FO" will be displayed. P- Pass or F- Fail will be displayed until the Zone/Cal button (left reading lamp button) is pressed and released or the ignition is cycled. If all of the tests pass, the Compass/Temp Mirror will display "P,'. A VF segment that fails to illuminate will not cause the Compass/Temp Mirror to display an "F". If any segment fails to illuminate or the Compass/Temp Mirror displays "F", the Compass/Temp Mirror must be replaced. To exit self-check diagnostics, press and release the Zone/Cal button or cycle the ignition to return to normal compass/temp operation. Ambient Temperature Sensor Diagnostics The outside temperature function is supported by the ambient temperature sensor; a signal and ground circuit hardwired to the compass/temp module (1.6L vehicles) or to the PCM (2.0L vehicles), and the Compass/Temp Mirror display. If the Compass/Temp Mirror display indicates 60 degrees C (140 degrees F) or the ambient temperature sensor sense circuit is shorted to ground, the temp display will be 60 degrees C (140 degrees F) to indicate a SHORT circuit condition. If the Compass/Temp Mirror display indicates -45 degrees C (-49 degrees F) or the ambient temperature sensor sense circuit is open, the temp display will be -45 degrees C (-49 degrees F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the Compass/Temp Mirror VF display can be tested. The ambient temperature sensor can be diagnosed using the following Sensor Test. If there are no codes stored in the PCM (2.0L vehicles) and the ambient temperature sensor and the circuits are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the Compass/Temp Mirror. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the ambient temperature sensor harness connector. 4. Measure the resistance of the ambient temperature sensor using the following values: 0 degrees C (32 degrees F) Sensor Resistance = 29.33 - 35.99 Kilohms 10 degrees C (50 degrees F) Sensor Resistance = 17.99 - 21.81 Kilohms 20 degrees C (68 degrees F) Sensor Resistance = 11.37 - 13.61 Kilohms 25 degrees C (77 degrees F) Sensor Resistance = 9.12 - 10.86 Kilohms 30 degrees C (86 degrees F) Sensor Resistance = 7.37 - 8.75 Kilohms 40 degrees C (104 degrees F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance value is OK, refer to the Wiring Diagrams to test the Signal and Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation > Page 7479 Ground circuits. If the resistance values are not OK, replace the Sensor. Refer to Body Control System. See: Body and Frame/Body Control Systems/Body Control Module Refer to The Programmable Communication Interface Multiplex System (PCI Bus). See: Powertrain Management/Computers and Control Systems/Information Bus Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7483 Fig. 27 Center Console - LHD Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Seat Belt Indicator ............................................................................................................................... .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7491 Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7492 Fig. 23 Door (Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7493 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7494 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7495 Fig. 44 Body (Right Rear) - RHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7496 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7497 Door Switch: Diagrams Driver Door Ajar Switch Hood Ajar Switch (Export) Left Rear Door Ajar Switch Passenger Door Ajar Switch Right Rear Door Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7501 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor (track). The resistor track is used to send electrical signals to the instrument cluster for fuel gauge operation and are then transmitted to the engine controller for OBDII emission requirements. For Fuel Gauge Operation: As fuel level increases, the float and arm move up. This increases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This decreases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the instrument cluster, the instrument cluster will transmit the data across the J1850 bus circuits to the PCM. For OBD II Emission Requirements: The voltage signal is sent to the instrument cluster to indicate fuel level. The cluster transmits the fuel level to the PCM where it is used to prevent a false setting of misfire and fuel system monitor trouble codes. This occurs if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7502 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDING UNIT/SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig.4 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 4). Fig.5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge (Fig. 5). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7503 Fig.6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 6). 4. Push level sensor signal and ground terminals out of the connector (Fig. 6). Fig.7 Level Sensor 5. Slide level sensor wires through opening fuel pump module (Fig. 7). 6. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 7). Ensure tab at bottom of sensor locks in place. 4. 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. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7507 Fig. 27 Center Console - LHD Fig. 55 Center Console - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Diagrams Shift Indicator: Diagrams Trans Range Indicator Illumination (PRNDL)(Autostick) Trans Range Indicator Illumination (PRNDL) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Application and ID Traction Control Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Trac OFF Indicator .............................................................................................................................. .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Application and ID Transmission Mode Indicator - A/T: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Console Gear Selector w/ Auto ........................................................................................................... .............................................................. PC 194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Application and ID Transmission Shift Position Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Shift Bezel (PRNDL) Lamp .................................................................................................................. ................................................................. T37 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Application and ID > Page 7520 Transmission Shift Position Indicator Lamp: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove floor console. 3. Remove wiring and socket from shift bezel (PRNDL). 4. Remove bulb from socket. INSTALLATION 1. Push bulb in socket and snap into place. 2. Install floor console. 3. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7526 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7527 Backup Lamp Switch (1.6/2.0L MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7528 Backup Lamp Switch: Service and Repair REMOVAL 1. Lift vehicle on hoist. Fig.1 Back-Up Lamp Switch 2. From bottom side of vehicle, disconnect back-up lamp switch connector. 3. Unscrew switch from transaxle. INSTALLATION 1. Install back-up lamp switch. Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.) torque. CAUTION: Do not overtighten switch. 2. Connect back-up lamp switch connector. 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views Brake Lamp: Connector Views Left Tail/Stop Lamp (Export) Left Tail/Stop/Turn Signal Lamp (Except Export) Right Tail/Stop Lamp (Export) Right Tail/Stop/Turn Signal Lamp (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 7533 Brake Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the table below. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Rear Tail/Stop/Turn Signal Lamp ......................................................................................................................................................... 3157 - P27/7W Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7538 Brake Light Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7539 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7540 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7541 Brake Lamp Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7542 Brake Light Switch: Service Precautions CAUTION: - The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. - Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7543 Brake Light Switch: Description and Operation BRAKE LAMP SWITCH Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. It has three internal switches controlling various functions of the vehicle. It's main function is to control operation of the vehicle's brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. When the brake pedal is pressed, the plunger on the outside of the brake lamp switch extends outward. This action opens or closes the contacts of the three switches inside the brake lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for terminals 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. A lever on the back of the switch is used to set the switch into the "adjusted" position. A non-adjusted switch will have the lever set to the diagonal position in relation to the switch housing. The plunger can be moved in and out, but the states of the internal switches will not change. CAUTION: Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Fig.5 Adjustment Lever Movement Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7544 Once installed in the vehicle as described in the brake lamp switch installation procedure, the new switch's adjustment lever is rotated to the adjusted position as indicated. This action locks the plunger to the internal switches. Once in this position the switch is permanently adjusted (or locked) and cannot be readjusted or released even if the lever is moved back. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7545 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH DIAGNOSIS NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position, it may have never been adjusted. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. Fig.3 Switch Test - Released Position 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the brake lamp switch in until it stops. Fig.4 Switch Test - Depressed Position 4. With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for any reason, a new switch must be installed and adjusted. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7546 Brake Light Switch: Service and Repair BRAKE LAMP SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Under the instrument panel, remove the brake lamp switch by rotating the switch in a counterclockwise direction approximately 30 degrees and pulling it out of the bracket. 3. Disconnect the wiring harness from the connector on the switch. 4. Discard the brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. This switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 1. Obtain NEW brake lamp switch. The adjustment lever on the new switch should be at a 45° angle from the wiring connector. If the adjustment lever is parallel with the wiring connector, the switch has been preset and must be scrapped. DO NOT ATTEMPT TO RESET (OR READJUST) THE BRAKE LAMP SWITCH. 2. Connect the wiring harness to the connector on the switch. 3. Mount and adjust the NEW brake lamp switch using the following steps: a. Install the switch in its bracket by aligning the index tab on the switch with the notch in the mounting bracket. b. When the switch body is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place. Fig.5 Adjustment Lever Movement c. With the brake pedal in the fully released position, move the adjustment lever on the brake lamp switch from the 45° angled non-adjusted position, clockwise as shown, until it is parallel with the wiring connector. The brake lamp switch is now properly adjusted to the vehicle. 4. Reconnect the battery negative terminal. 5. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 6. Road test the vehicle to ensure proper operation of the brakes (including ABS if equipped) and speed control (if equipped). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Cargo Lamp Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 7550 Cargo Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Rear Cargo .......................................................................................................................................... .................................................................. T906 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center High Mounted Stop Lamp Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 7554 Center Mounted Brake Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the table below. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Center High Mounted Stop Lamp (CHMSL) .................................................................................................................................................... W16W Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement Center Mounted Brake Lamp: Service and Repair Center High Mounted Stop Lamp (CHMSL) Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove bulb socket from center high mounted stop lamp. 3. Pull bulb from socket. INSTALLATION 1. Install bulb into socket. 2. Install bulb socket into center high mounted stop lamp. 3. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement > Page 7557 Center Mounted Brake Lamp: Service and Repair Center High Mounted Stop Lamp Unit (CHMSL) Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove socket and bulb from lamp. 3. Remove nuts attaching center high mounted stop lamp to deck lid. 4. Remove CHMSL from deck lid. INSTALLATION 1. Place CHMSL into position on deck lid. 2. Install nuts attaching CHMSL to deck lid. 3. Install socket and bulb into lamp. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair Glove Box Lamp: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable 2. Open glove box door. 3. Pull downward on lamp/switch assembly to disengage tabs from instrument panel. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Place lamp/switch assembly into position. 3. Push lamp/switch assembly to lock tabs. 4. Check lamp operation, and close glove door. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 and isolate the battery negative cable 2. Open glove box door. 3. Pull downward on lamp/switch assembly to disengage tabs from instrument panel. 4. Pull bulb from socket. 5. Disconnect wire connector from lamp and remove glove box lamp/switch. INSTALLATION 1. Push bulb into socket. 2. Place lamp/switch assembly into position. 3. Connect wire connector to the lamp/switch. 4. Push lamp/switch assembly to lock tabs. 5. Check lamp operation, and close glove box door. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation EXTERIOR LIGHTING The Headlamps are controlled by the Instrument Cluster. The Instrument Cluster is also referred to as a "Smart Cluster". It receives and sends messages to other modules through the PCI BUS circuit. The Headlamps are wired through the cluster and then go to the Fuse Block to the lamps. Each Headlamp has an independent fuse located in the Fuse Block. For vehicles equipped with Daytime Running Lamps, the DRL Module is integrated with the Instrument Cluster. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams Dome Lamp: Diagrams Dome Lamp (Except Export) Dome Lamp/Intrusion Sensor (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 7571 Dome Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Dome Lamp ......................................................................................................................................... ................................................................. T579 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 7572 Dome Lamp: Service and Repair REMOVAL Lamp 1. Disconnect and isolate the battery negative cable. 2. Insert a trim stick between the dome lamp bezel and dome lamp lens. 3. Carefully pull down on lamp lens to remove lamp from headliner. 4. Disconnect wire connector. 5. Remove lamp. Bulb 1. Disconnect and isolate the battery negative cable. 2. Insert a trim stick between the dome lamp bezel and dome lamp lens. 3. Carefully swing down one side of the lamp lens. 4. Remove bulb from lamp socket. INSTALLATION Lamp 1. Place lamp into position. 2. Connect wire connector. 3. Install dome lamp and lens. 4. Connect the battery negative cable. Bulb 1. Push bulb in socket and snap into place. 2. Position lens on lamp and snap into place. 3. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7576 Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7577 Fig. 23 Door (Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7578 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7579 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7580 Fig. 44 Body (Right Rear) - RHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7581 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7582 Door Switch: Diagrams Driver Door Ajar Switch Hood Ajar Switch (Export) Left Rear Door Ajar Switch Passenger Door Ajar Switch Right Rear Door Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Indicator > Component Information > Application and ID Fog/Driving Lamp Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Front Fog Lamp Indicator .................................................................................................................... .................................................................. LED Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Fig. 6 Front Fog Lamps - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 7590 Fog/Driving Lamp Switch: Diagrams Left Front Fog Lamp Right Front Fog Lamp (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 7591 Fog/Driving Lamp Switch: Description and Operation REAR FOG LAMP SWITCH (EXPORT) The Rear Fog Lamp Switch is located on the left stalk of the multi-function switch assembly. The rear fog lamp switch is the primary controller of the rear fog lamps. With the end of the left stalk pulled out, rotate it past the headlamp position to complete the rear fog lamp switch circuit. This illuminates the rear fog lamp or lamps. Headlamps must be ON in order for the rear fog lamp/s to function. Refer to Wiring Diagrams for a complete system schematic. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 7592 Fog/Driving Lamp Switch: Service and Repair REAR FOG LAMP SWITCH (EXPORT) REMOVAL AND INSTALLATION Refer to MULTI-FUNCTION SWITCH. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Fig.6 Combination Flasher Location The flasher is mounted to the back side of the multi-function switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7597 Hazard Warning Flasher: Description and 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 is a smart relay located on the back of the multi-function switch. The combo-flasher is black in color and has a dampener material wrapped on it. Constant battery voltage is supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. However, when the flasher is idle no current is drawn through the module. The unit does not become active until it is provided a signal ground from the turn signal switch or hazard warning switch. 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. Typical flash rate is about ninety flashes per minute. When a bulb is burnt out, or when a circuit for a lamp is open, the turn signal flash rate will increase to a minimum of 180 flashes per minute. However, an open lamp circuit or burnt out bulb does not change the hazard warning flash rate. Turn signal inputs that actuate the combination flasher are low current grounds, each drawing a maximum of 300 milliamperes. The turn signal inputs are provided to the flasher through the multifunction switch on the steering column. The hazard warning signal input is a low current ground drawing a maximum of 600 milliamperes. The hazard warning input can be provided through the multifunction switch on the steering column. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7598 Hazard Warning Flasher: Service and Repair COMBINATION FLASHER REMOVAL Fig.6 Combination Flasher Location The flasher is mounted to the back side of the multi-function switch. 1. To gain access, the upper steering column shroud must be removed. 2. The flasher can be removed by pulling it toward the instrument cluster (forward). NOTE: The flasher is serviced separately from the multifunction switch. INSTALLATION The flasher is serviced separately from the multifunction switch. 1. The flasher can be installed by pushing it toward the back of the steering wheel. 2. Install the upper steering column shroud. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 7602 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 7603 Hazard Warning Switch: Description and Operation Fig.18 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. The visible parts of the multi-function switch are the turn signal control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, the windshield wiper/washer, exterior lighting control stalk that extends through a dedicated opening in the right upper steering column shrouds, the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A connector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Washer Mode - A button on the end of the control stalk of the multi-function switch provides washer system operation when the button is depressed towards the steering column. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Exterior Lighting Control - The internal circuitry and hardware of the multi-function switch provide for activation and deactivation of exterior lighting. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Control Module > Component Information > Diagrams Headlamp Alignment Control Module: Diagrams Left Lavelier Module (Export) Right Lavalier Module (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Motor > Component Information > Description and Operation Headlamp Motor: Description and Operation HEADLAMP LEVELING MOTOR - EXPORT Two leveling motors are used per vehicle, one for each headlamp. These leveling motors are attached to the rear of the headlamp mounting brackets. They can be described as a small semi-square shaped module with a electrical connector attached to one side. Due to vehicle design these motors can only be serviced or accessed from the under side of the vehicle. The headlamp leveling motors move the headlamp and beam pattern according to the signal received from the headlamp leveling switch. With the vehicles headlamps "ON," a signal voltage is sent from the headlamp leveling switch and received at each of the headlamp leveling motors. This signal voltage (typically 2-9 volts) tells the headlamp leveling motors were to position the headlamps. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Motor > Component Information > Description and Operation > Page 7611 Headlamp Leveling Motor Diagnosis Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Motor > Component Information > Description and Operation > Page 7612 Headlamp Motor: Service and Repair Headlamp Leveling Motor Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate headlamp unit. Fig.12 Headlamp Leveling Motor 3. Disconnect the headlamp leveling motor electrical connector. Depress the steel retaining clip while pulling the connector from the motor. 4. Rotate the headlamp leveling motor and pull it straight out of the headlamp module. NOTE: Significant force will be required to unsnap the ball and socket connection between the headlamp leveling motor and the headlamp unit. 5. Separate the ball and socket from the motor. INSTALLATION 1. Install the headlamp leveling motor in the headlamp unit. Push the headlamp leveling motor pushrod straight into its mating socket while holding the headlamp unit in the fully retracted position. 2. Once the ball and socket connection is secured, push and rotate the headlamp leveling motor into the headlamp unit to lock in place. 3. Connect the headlamp leveling motor electrical connector. 4. Install the headlamp unit. 5. Connect the battery negative cable. 6. Verify system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations Fig.12 Headlamp Leveling Switch Location HEADLAMP LEVELING SWITCH The Headlamp Leveling Switch is located on the center instrument panel area in the accessory switch bezel and is the primary controller of the headlamp leveling system. HEADLAMP SWITCH The headlamp switch is integral to the left stalk of the multi-function switch located on the steering column behind the steering wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Component Locations > Page 7617 Headlamp Switch: Connector Locations Fig. 12 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Component Locations > Page 7618 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7619 Headlamp Switch: Description and Operation Fig.13 Headlamp Leveling Switch Location HEADLAMP LEVELING SWITCH - EXPORT The Headlamp Leveling Switch is located on the center instrument panel area in the accessory switch bezel, and is the primary controller of the headlamp leveling system The leveling switch has four settings 0-3, 0 being the lowest, and 3 being the highest headlamp beam vertical setting With the rotation of the headlamp leveling switch control knob, voltage is adjusted at the headlamp leveling switch (rheostat) This signals the headlamp leveling motors (headlamp module mounted) to adjust the vertical headlamp beam pattern accordingly Headlamps must be "ON" in order for the leveling system to function Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7620 Headlamp Switch: Testing and Inspection HEADLAMP LEVELING SWITCH - EXPORT 1. Disconnect and isolate the negative battery cable 2. Remove the headlamp leveling switch. Headlamp Leveling Switch Resistance 3. Using an ohmmeter and the HEADLAMP LEVELING SWITCH RESISTANCE table, check the resistance between switch connector pins 1&2. 4. If the test results are not as indicated in the table below, replace the switch If test results are as indicated below, the switch is OK. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7621 Headlamp Switch: Service and Repair Headlamp Leveling Switch Replacement REMOVAL 1. Rotate the A/C outlet registers to the full down position Grip each outlet at its outboard end and gently over-rotate to release from its pivot point Swing outlet straight out and remove by hand 2. Remove the (4) HVAC control knobs by pulling straight off the switch shaft 3. Remove the (2) screws from the center instrument bezel 4. Remove the center instrument bezel Pull it straight out to unsnap the (4) retaining clips 5. Remove the (2) screws from the accessory switch bank 6. Pull the accessory switch bank out and disconnect the electrical connector from the headlamp leveling switch. Fig.14 Leveling Switch Removal 7. Gently pry the headlamp leveling switch out of its mounting clips. INSTALLATION 1. Snap the headlamp leveling switch into the accessory switch bank. 2. Install the headlamp leveling switch electrical connector. 3. Verify switch operation. 4. Position the accessory switch bank and install the (4) retaining screws. 5. Snap the center instrument bezel in position and install the retaining screws. 6. Install the (4) HVAC control knobs. 7. Install the A/C outlet registers on the center instrument bezel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Application and ID Hi-Beam Indicator Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application High Beam Lamp Indicator .................................................................................................................. .............................................................. PC194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7629 Horn Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7630 Horn Relay: Testing and Inspection 1. Remove horn relay from Power Distribution Center (PDC). 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/HORN - DIAGNOSIS AND TESTING). 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. Fig. 2 Horn Relay 5. Click relay for 70 to 75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7631 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center cover and locate the horn relay. 3. Remove the horn relay. INSTALLATION 1. Insert the horn relay into the Power Distribution Center (PDC). 2. Install the PDC cover 3. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7635 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7636 Horn Switch: Description and Operation 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7637 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove horn relay from the 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 RESTRAINTS/DRIVER AIRBAG - REMOVAL). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7638 Horn Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Driver Airbag Module. (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). 3. Clip off strap tie holding the horn switch wire to the airbag module. 4. Unclip horn switch wire connector from airbag module. 5. Remove four torx screws from top side of airbag module. 6. Fold airbag module cover down to expose the horn switch. 7. Lift the horn switch off indexing tabs and remove from vehicle. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install horn switch to the indexing tabs on the airbag module. 2. Install screws to the top of airbag module. 3. Reconnect horn switch connector to airbag module. 4. Install the airbag module. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Plate Lamp: Connector Views Left License Lamp (Export) License Lamp (Except Export) Right License Lamp (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 7643 License Plate Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the table below. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application License Plate Lamp ............................................................................................................................. .................................................................... 168 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement License Plate Lamp: Service and Repair License Plate Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.17 License Plate Lamp 2. Remove screws attaching license plate lamp to rear bumper fascia. 3. Remove lamp from bumper fascia. 4. Remove bulb socket from lamp. 5. Pull bulb from socket. INSTALLATION 1. Install bulb into socket. 2. Install bulb socket into lamp. 3. Place lamp in position. 4. Install screws attaching license plate lamp to rear bumper fascia. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement > Page 7646 License Plate Lamp: Service and Repair License Plate Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.17 License Plate Lamp 2. Remove screws attaching license plate lamp to rear bumper fascia. 3. Remove lamp from rear bumper fascia. 4. Remove bulb socket from lamp. 5. Remove lamp. INSTALLATION 1. Install bulb socket into lamp. 2. Place lamp in position. 3. Install screws attaching license plate lamp to rear bumper fascia. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams Map Light: Diagrams Center Stack Lamp (Light Package/Export) Map/Reading Lamps Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 7650 Map Light: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small thin blade tool, pry at the center of the lens nearest the mirror to remove lens. 3. Remove cartridge lamp. INSTALLATION 1. Install lens by setting lens into position and applying pressure until it is locked into position. 2. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams Marker Lamp: Diagrams Left Front Side Marker Lamp (Except Export) Right Front Side Marker Lamp (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 7654 Marker Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the table below. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Front Side Marker Lamp ...................................................................................................................... ................................................................... 168 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Marker Lamp Replacement Marker Lamp: Service and Repair Marker Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Fog Lamp/Fog Lamp Unit - Remove/Install Fig.8 Fog Lamp - Canada/Export/RHD 2. Reach behind front bumper fascia forward of front wheel and remove attaching clip from the front side marker lamp. 3. Remove lamp from front fascia. 4. Remove bulb from socket. INSTALLATION 1. Install bulb into socket. 2. Install bulb socket into lamp unit 3. Install lamp unit into front fascia. 4. Install attaching clip to the front side market lamp unit. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Marker Lamp Replacement > Page 7657 Marker Lamp: Service and Repair Marker Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.7 Fog Lamp/Fog Lamp Unit - Remove/Install Fig.8 Fog Lamp - Canada/Export/RHD 2. Reach behind front bumper fascia forward of front wheel and remove attaching clip from the front side marker lamp. 3. Remove lamp. 4. Remove bulb from socket. INSTALLATION 1. Install bulb socket into lamp. 2. Place lamp into front fascia. 3. Install attaching clip to the front side marker lamp. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views Parking Lamp: Connector Views Left Park/Turn Signal Lamp (Except Export) Right Park/Turn Signal Lamp (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 7662 Parking Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the table below. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Front Park/Turn Signal Lamp .............................................................................................................. ......................................................... 4157NAK Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 7663 Parking Lamp: Description and Operation FRONT POSITION LAMPS - EXPORT Some vehicles are equipped with front position lamps. One front position lamp is incorporated into each of the headlamps. These lamps utilize a clear lens and clear bulb and function in the same way that Parking Lamps do on other market built vehicles (U.S., Canada). The front position lamp is built in to the headlamp and therefore doesn't require its own lamp housing. The front position lamps are turned on or off with the multi-function switch. These lamps function in the same way that the parking lamps do on other market built vehicles.(U.S., Canada). Refer to Wiring Diagrams for a complete schematic. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 7664 Parking Lamp: Testing and Inspection Front Position Lamps Test The following test is designed to diagnosis a faulty front position lamp. NOTE: Battery must be completely charged (12 volt) prior to testing. It may also be necessary to install battery charger on the vehicles electrical system when performing this test. Refer to the Battery for detailed information. 1. Remove the front position lamp bulb and check for burned out condition, replace bulb if necessary. 2. If bulb appears OK, reinstall the bulb in its socket and rotate the left side multi-function switch one detent position and check for lamp operation. If lamp is still inoperative proceed to step # 3. 3. Remove lamp bulb and check for proper power (12 volt) and ground connections in lamp socket. If power and I or ground connections are not present, trace wire until open or short is found. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 7665 Parking Lamp: Service and Repair REMOVAL 1. Remove the 2 screws holding the headlamp bezel in place and remove the bezel. 2. Remove the 4 screws holding the headlamp and remove the headlamp. 3. Pull the front position lamp straight from headlamp. 4. Remove the front position lamp bulb from its socket by rotating counter-clockwise. INSTALLATION 1. Install the front position lamp bulb into its socket by rotating clockwise. 2. Push the front position lamp straight into the headlamp. 3. Install the headlamp and the 4 screws holding the headlamp. 4. Install the headlamp bezel and the 2 screws holding the headlamp bezel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Alignment Control Module > Component Information > Diagrams Headlamp Alignment Control Module: Diagrams Left Lavelier Module (Export) Right Lavalier Module (Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Power Distribution Center Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7673 Horn Relay Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7674 Horn Relay: Testing and Inspection 1. Remove horn relay from Power Distribution Center (PDC). 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/HORN - DIAGNOSIS AND TESTING). 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. Fig. 2 Horn Relay 5. Click relay for 70 to 75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7675 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center cover and locate the horn relay. 3. Remove the horn relay. INSTALLATION 1. Insert the horn relay into the Power Distribution Center (PDC). 2. Install the PDC cover 3. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 7680 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 7681 Backup Lamp Switch (1.6/2.0L MTX) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 7682 Backup Lamp Switch: Service and Repair REMOVAL 1. Lift vehicle on hoist. Fig.1 Back-Up Lamp Switch 2. From bottom side of vehicle, disconnect back-up lamp switch connector. 3. Unscrew switch from transaxle. INSTALLATION 1. Install back-up lamp switch. Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.) torque. CAUTION: Do not overtighten switch. 2. Connect back-up lamp switch connector. 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7687 Brake Light Switch: Connector Locations Fig. 3 Engine Compartment (Left Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7688 Fig. 39 Engine Compartment (Left Front) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7689 Fig. 49 Dash Panel/Plenum - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7690 Brake Lamp Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7691 Brake Light Switch: Service Precautions CAUTION: - The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. - Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7692 Brake Light Switch: Description and Operation BRAKE LAMP SWITCH Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. It has three internal switches controlling various functions of the vehicle. It's main function is to control operation of the vehicle's brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. When the brake pedal is pressed, the plunger on the outside of the brake lamp switch extends outward. This action opens or closes the contacts of the three switches inside the brake lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for terminals 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. A lever on the back of the switch is used to set the switch into the "adjusted" position. A non-adjusted switch will have the lever set to the diagonal position in relation to the switch housing. The plunger can be moved in and out, but the states of the internal switches will not change. CAUTION: Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Fig.5 Adjustment Lever Movement Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7693 Once installed in the vehicle as described in the brake lamp switch installation procedure, the new switch's adjustment lever is rotated to the adjusted position as indicated. This action locks the plunger to the internal switches. Once in this position the switch is permanently adjusted (or locked) and cannot be readjusted or released even if the lever is moved back. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7694 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH DIAGNOSIS NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position, it may have never been adjusted. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. Fig.3 Switch Test - Released Position 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the brake lamp switch in until it stops. Fig.4 Switch Test - Depressed Position 4. With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for any reason, a new switch must be installed and adjusted. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7695 Brake Light Switch: Service and Repair BRAKE LAMP SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Under the instrument panel, remove the brake lamp switch by rotating the switch in a counterclockwise direction approximately 30 degrees and pulling it out of the bracket. 3. Disconnect the wiring harness from the connector on the switch. 4. Discard the brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. This switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 1. Obtain NEW brake lamp switch. The adjustment lever on the new switch should be at a 45° angle from the wiring connector. If the adjustment lever is parallel with the wiring connector, the switch has been preset and must be scrapped. DO NOT ATTEMPT TO RESET (OR READJUST) THE BRAKE LAMP SWITCH. 2. Connect the wiring harness to the connector on the switch. 3. Mount and adjust the NEW brake lamp switch using the following steps: a. Install the switch in its bracket by aligning the index tab on the switch with the notch in the mounting bracket. b. When the switch body is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place. Fig.5 Adjustment Lever Movement c. With the brake pedal in the fully released position, move the adjustment lever on the brake lamp switch from the 45° angled non-adjusted position, clockwise as shown, until it is parallel with the wiring connector. The brake lamp switch is now properly adjusted to the vehicle. 4. Reconnect the battery negative terminal. 5. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 6. Road test the vehicle to ensure proper operation of the brakes (including ABS if equipped) and speed control (if equipped). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7699 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7700 Multi-Function Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7701 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH Turn Signal And Hazard Warning Flasher Diagnosis Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7702 Turn Signal And Hazard Warning Flasher Diagnosis FLASHER DIAGNOSIS Should any function of the multi-function switch fail, the entire switch assembly must be replaced. SWITCH DIAGNOSIS To test the switch: 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shrouds. 3. Disconnect the switch connector. Fig.19 Combination Flasher Connector (A) Fig.20 Multi-Function Switch Connector (B) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7703 Fig.21 Windshield Wiper/Washer Switch Connector (C) Multi-Function Switch Continuity Test Part 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7704 Multi-Function Switch Continuity Test Part 2 Multi-Function Switch Dimmer Control Resistance Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the Multi-Function Switch Continuity Test table for diagnosis. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7705 Combination Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL Fig.22 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove both upper and lower steering column shrouds. Fig.23 Multi-Function Switch Mounting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7706 Fig.24 Multi-Function Switch - Remove/Install 3. Disconnect both posi-lock harness connectors at the rear of the multi-function switch. 4. Remove multi-function switch mounting screws. 5. The combination flasher must be transferred to new multi-function switch if replacing. 6. The windshield wiper/washer switch must be transferred to the new multi-function switch. INSTALLATION 1. The windshield wiper/washer switch must be transferred to the new multi-function switch. 2. The combination flasher must be transferred to new multi-function switch if replacing. 3. Install the multi-function switch mounting screws. Tighten multi-function switch to column retaining screws to 3 Nm (27 in. lbs.) torque. 4. Connect both posi-lock harness connectors at the rear of the multi-function switch. 5. Instal both upper and lower steering column shrouds. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Fig. 1 Engine Compartment - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7710 Driver Door - LHD Passenger Door - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7711 Fig. 23 Door (Rear) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7712 Fig. 25 Engine Compartment - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7713 Fig. 29 Engine Compartment (Right Side) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7714 Fig. 44 Body (Right Rear) - RHD Fig. 45 Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7715 Door (Driver) - RHD Fig. 47 Door (Rear) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7716 Door Switch: Diagrams Driver Door Ajar Switch Hood Ajar Switch (Export) Left Rear Door Ajar Switch Passenger Door Ajar Switch Right Rear Door Ajar Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fig. 6 Front Fog Lamps - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 7720 Fog/Driving Lamp Switch: Diagrams Left Front Fog Lamp Right Front Fog Lamp (2.0L) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 7721 Fog/Driving Lamp Switch: Description and Operation REAR FOG LAMP SWITCH (EXPORT) The Rear Fog Lamp Switch is located on the left stalk of the multi-function switch assembly. The rear fog lamp switch is the primary controller of the rear fog lamps. With the end of the left stalk pulled out, rotate it past the headlamp position to complete the rear fog lamp switch circuit. This illuminates the rear fog lamp or lamps. Headlamps must be ON in order for the rear fog lamp/s to function. Refer to Wiring Diagrams for a complete system schematic. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 7722 Fog/Driving Lamp Switch: Service and Repair REAR FOG LAMP SWITCH (EXPORT) REMOVAL AND INSTALLATION Refer to MULTI-FUNCTION SWITCH. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 and isolate the battery negative cable 2. Open glove box door. 3. Pull downward on lamp/switch assembly to disengage tabs from instrument panel. 4. Pull bulb from socket. 5. Disconnect wire connector from lamp and remove glove box lamp/switch. INSTALLATION 1. Push bulb into socket. 2. Place lamp/switch assembly into position. 3. Connect wire connector to the lamp/switch. 4. Push lamp/switch assembly to lock tabs. 5. Check lamp operation, and close glove box door. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 7729 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 7730 Hazard Warning Switch: Description and Operation Fig.18 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. The visible parts of the multi-function switch are the turn signal control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, the windshield wiper/washer, exterior lighting control stalk that extends through a dedicated opening in the right upper steering column shrouds, the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A connector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Washer Mode - A button on the end of the control stalk of the multi-function switch provides washer system operation when the button is depressed towards the steering column. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Exterior Lighting Control - The internal circuitry and hardware of the multi-function switch provide for activation and deactivation of exterior lighting. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations Fig.12 Headlamp Leveling Switch Location HEADLAMP LEVELING SWITCH The Headlamp Leveling Switch is located on the center instrument panel area in the accessory switch bezel and is the primary controller of the headlamp leveling system. HEADLAMP SWITCH The headlamp switch is integral to the left stalk of the multi-function switch located on the steering column behind the steering wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 7735 Headlamp Switch: Connector Locations Fig. 12 Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 7736 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7737 Headlamp Switch: Description and Operation Fig.13 Headlamp Leveling Switch Location HEADLAMP LEVELING SWITCH - EXPORT The Headlamp Leveling Switch is located on the center instrument panel area in the accessory switch bezel, and is the primary controller of the headlamp leveling system The leveling switch has four settings 0-3, 0 being the lowest, and 3 being the highest headlamp beam vertical setting With the rotation of the headlamp leveling switch control knob, voltage is adjusted at the headlamp leveling switch (rheostat) This signals the headlamp leveling motors (headlamp module mounted) to adjust the vertical headlamp beam pattern accordingly Headlamps must be "ON" in order for the leveling system to function Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7738 Headlamp Switch: Testing and Inspection HEADLAMP LEVELING SWITCH - EXPORT 1. Disconnect and isolate the negative battery cable 2. Remove the headlamp leveling switch. Headlamp Leveling Switch Resistance 3. Using an ohmmeter and the HEADLAMP LEVELING SWITCH RESISTANCE table, check the resistance between switch connector pins 1&2. 4. If the test results are not as indicated in the table below, replace the switch If test results are as indicated below, the switch is OK. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7739 Headlamp Switch: Service and Repair Headlamp Leveling Switch Replacement REMOVAL 1. Rotate the A/C outlet registers to the full down position Grip each outlet at its outboard end and gently over-rotate to release from its pivot point Swing outlet straight out and remove by hand 2. Remove the (4) HVAC control knobs by pulling straight off the switch shaft 3. Remove the (2) screws from the center instrument bezel 4. Remove the center instrument bezel Pull it straight out to unsnap the (4) retaining clips 5. Remove the (2) screws from the accessory switch bank 6. Pull the accessory switch bank out and disconnect the electrical connector from the headlamp leveling switch. Fig.14 Leveling Switch Removal 7. Gently pry the headlamp leveling switch out of its mounting clips. INSTALLATION 1. Snap the headlamp leveling switch into the accessory switch bank. 2. Install the headlamp leveling switch electrical connector. 3. Verify switch operation. 4. Position the accessory switch bank and install the (4) retaining screws. 5. Snap the center instrument bezel in position and install the retaining screws. 6. Install the (4) HVAC control knobs. 7. Install the A/C outlet registers on the center instrument bezel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7743 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7744 Horn Switch: Description and Operation 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. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7745 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove horn relay from the 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 RESTRAINTS/DRIVER AIRBAG - REMOVAL). 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7746 Horn Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Driver Airbag Module. (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). 3. Clip off strap tie holding the horn switch wire to the airbag module. 4. Unclip horn switch wire connector from airbag module. 5. Remove four torx screws from top side of airbag module. 6. Fold airbag module cover down to expose the horn switch. 7. Lift the horn switch off indexing tabs and remove from vehicle. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install horn switch to the indexing tabs on the airbag module. 2. Install screws to the top of airbag module. 3. Reconnect horn switch connector to airbag module. 4. Install the airbag module. 5. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Component Locations Turn Signal Switch: Component Locations The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Component Locations > Page 7751 Turn Signal Switch: Connector Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Component Locations > Page 7752 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 7753 Multi-Function Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 7754 Turn Signal Switch: Description and Operation Fig.18 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. The visible parts of the multi-function switch are the turn signal control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, the windshield wiper/washer, exterior lighting control stalk that extends through a dedicated opening in the right upper steering column shrouds, the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A connector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Washer Mode - A button on the end of the control stalk of the multi-function switch provides washer system operation when the button is depressed towards the steering column. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Exterior Lighting Control - The internal circuitry and hardware of the multi-function switch provide for activation and deactivation of exterior lighting. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views Tail Lamp: Connector Views Left Tail/Stop Lamp (Export) Left Tail/Stop/Turn Signal Lamp (Except Export) Right Tail/Stop Lamp (Export) Right Tail/Stop/Turn Signal Lamp (Except Export) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 7759 Tail Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the table below. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Rear Tail/Stop/Turn Signal Lamp ......................................................................................................................................................... 3157 - P27/7W Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement Tail Lamp: Service and Repair Tail Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Move trunk lining as necessary from rear closure panel to gain access to back of tail lamp. Fig.26 Tail And Stop Lamp Bulb 3. Remove bulb socket from tail lamp through openings in rear closure panel. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Install bulb socket into tail lamp through openings in rear closure panel. 3. Reposition trunk lining to rear closure panel. 4. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement > Page 7762 Tail Lamp: Service and Repair Tail Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Move trunk lining as necessary from rear closure panel to gain access to back of tail lamp. 3. Remove nuts attaching tail lamp to the rear closure panel. 4. Disconnect the wiring connectors and bulbs from unit by twisting bulb counterclockwise. 5. Remove lamp housing from vehicle. INSTALLATION 1. Place lamp housing into position. 2. Install the bulbs into bulb pockets and rotate clockwise. 3. Install nuts attaching tail lamp to the rear closure panel. 4. Reposition trunk lining to rear closure panel. 5. Connect the battery negative cable. 6. Verify vehicle and system operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair Trunk Lamp: Service and Repair Trunk Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a trim stick or small flat blade between the lamp lens and rear shelf reinforcement panel. 3. Pry the lamp lens downward. 4. Disconnect wire connector. 5. Remove lamp from vehicle. INSTALLATION 1. Place lamp into position. 2. Connect wire connector. 3. Install lamp lens. 4. Connect battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7770 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7771 Multi-Function Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7772 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH Turn Signal And Hazard Warning Flasher Diagnosis Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7773 Turn Signal And Hazard Warning Flasher Diagnosis FLASHER DIAGNOSIS Should any function of the multi-function switch fail, the entire switch assembly must be replaced. SWITCH DIAGNOSIS To test the switch: 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shrouds. 3. Disconnect the switch connector. Fig.19 Combination Flasher Connector (A) Fig.20 Multi-Function Switch Connector (B) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7774 Fig.21 Windshield Wiper/Washer Switch Connector (C) Multi-Function Switch Continuity Test Part 1 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7775 Multi-Function Switch Continuity Test Part 2 Multi-Function Switch Dimmer Control Resistance Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the Multi-Function Switch Continuity Test table for diagnosis. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7776 Combination Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL Fig.22 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove both upper and lower steering column shrouds. Fig.23 Multi-Function Switch Mounting Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7777 Fig.24 Multi-Function Switch - Remove/Install 3. Disconnect both posi-lock harness connectors at the rear of the multi-function switch. 4. Remove multi-function switch mounting screws. 5. The combination flasher must be transferred to new multi-function switch if replacing. 6. The windshield wiper/washer switch must be transferred to the new multi-function switch. INSTALLATION 1. The windshield wiper/washer switch must be transferred to the new multi-function switch. 2. The combination flasher must be transferred to new multi-function switch if replacing. 3. Install the multi-function switch mounting screws. Tighten multi-function switch to column retaining screws to 3 Nm (27 in. lbs.) torque. 4. Connect both posi-lock harness connectors at the rear of the multi-function switch. 5. Instal both upper and lower steering column shrouds. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Fig.6 Combination Flasher Location The flasher is mounted to the back side of the multi-function switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7781 Turn Signal Flasher: Description and 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 is a smart relay located on the back of the multi-function switch. The combo-flasher is black in color and has a dampener material wrapped on it. Constant battery voltage is supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. However, when the flasher is idle no current is drawn through the module. The unit does not become active until it is provided a signal ground from the turn signal switch or hazard warning switch. 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. Typical flash rate is about ninety flashes per minute. When a bulb is burnt out, or when a circuit for a lamp is open, the turn signal flash rate will increase to a minimum of 180 flashes per minute. However, an open lamp circuit or burnt out bulb does not change the hazard warning flash rate. Turn signal inputs that actuate the combination flasher are low current grounds, each drawing a maximum of 300 milliamperes. The turn signal inputs are provided to the flasher through the multifunction switch on the steering column. The hazard warning signal input is a low current ground drawing a maximum of 600 milliamperes. The hazard warning input can be provided through the multifunction switch on the steering column. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7782 Turn Signal Flasher: Service and Repair COMBINATION FLASHER REMOVAL Fig.6 Combination Flasher Location The flasher is mounted to the back side of the multi-function switch. 1. To gain access the upper steering column shroud must be removed. Refer to Steering, Column, Column Shroud, Removal. 2. The flasher can be removed by pulling it toward the instrument cluster (forward). The flasher is serviced separately from the multifunction switch. INSTALLATION The flasher is serviced separately from the multifunction switch. 1. The flasher can be installed by pushing it toward the back of the steering wheel. 2. Install the upper steering column shroud. Refer to Steering, Column, Column Shroud, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Application and ID Turn Signal Indicator: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Turn Signal Indicator ........................................................................................................................... .............................................................. PC194 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair Side Repeater Lamp Bulb REMOVAL 1. Working in the appropriate front wheel well, remove the rear-most fasteners from the front wheel-house liner. Refer to Body for detailed instructions. 2. Reach up behind the side repeater lamp and depress the two lamp housing retaining tabs. Remove the lamp housing from the fender opening. 3. Rotate the side repeater lamp housing counterclockwise and remove the lamp socket from the lamp housing. 4. Pull the lamp bulb straight from its socket. INSTALLATION 1. Install the side repeater lamp bulb in the socket. 2. Verify lamp operation. 3. Install the side repeater lamp socket into the lamp housing. 4. Install the side repeater lamp in the front fender. Be certain lamp is secure in fender. 5. Install the front wheelhouse liner. Refer to Body for detailed instructions. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Component Locations Turn Signal Switch: Component Locations The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Component Locations > Page 7794 Turn Signal Switch: Connector Locations Fig. 10 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Component Locations > Page 7795 Fig. 36 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 7796 Multi-Function Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 7797 Turn Signal Switch: Description and Operation Fig.18 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured to the upper steering column housing at the top of the steering column, just below the steering wheel. The visible parts of the multi-function switch are the turn signal control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, the windshield wiper/washer, exterior lighting control stalk that extends through a dedicated opening in the right upper steering column shrouds, the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A connector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Washer Mode - A button on the end of the control stalk of the multi-function switch provides washer system operation when the button is depressed towards the steering column. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Exterior Lighting Control - The internal circuitry and hardware of the multi-function switch provide for activation and deactivation of exterior lighting. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Application and ID Underhood Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Underhood ........................................................................................................................................... .................................................................... 105 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Application and ID Vanity Lamp: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Visor Vanity ......................................................................................................................................... ........................................................... 6501966 Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Application and ID > Page 7804 Vanity Lamp: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower visor. 3. Insert a small flat bladed tool between the lamp lens and lamp. 4. Carefully pry lens outward. 5. Remove bulb from socket. INSTALLATION 1. Position bulb in socket and snap into place. 2. Position lens on lamp and snap into place. 3. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 7810 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 7811 Rear Window Defogger Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 7812 Heated Glass Element Switch: Testing and Inspection The rear window defogger switch may be tested in the vehicle or out of the vehicle, on the bench. IN-VEHICLE TESTING 1. Remove the switch from the instrument panel but leave the switch connected. 2. Turn the ignition switch ON. Rear Window Defogger Switch Harness Connector 3. Using a voltmeter, check for battery voltage at Pin 1 and 2. a. If OK, go to Step 4. b. If NOT OK, check fuse 7 in the fuse block and the 40 Amp cartridge 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. 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. BENCH TESTING 1. First remove switch. Rear Window Defogger Switch Connector 2. With switch removed from vehicle, use a jumper wire and connect a 12 volt supply to Pin 1 and 2. Using a third jumper wire, ground Pin 3. Refer to and the Rear Window Defogger Switch and Harness Connector Pin Call-Outs table. 3. Follow the same procedures used for IN-VEHICLE TESTING, except for step Step 2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations Instrument Panel (Right Side) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 7817 Instrument Panel (Left) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 7818 Rear Window Defogger Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 7819 Heated Glass Element Switch: Testing and Inspection The rear window defogger switch may be tested in the vehicle or out of the vehicle, on the bench. IN-VEHICLE TESTING 1. Remove the switch from the instrument panel but leave the switch connected. 2. Turn the ignition switch ON. Rear Window Defogger Switch Harness Connector 3. Using a voltmeter, check for battery voltage at Pin 1 and 2. a. If OK, go to Step 4. b. If NOT OK, check fuse 7 in the fuse block and the 40 Amp cartridge 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. 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. BENCH TESTING 1. First remove switch. Rear Window Defogger Switch Connector 2. With switch removed from vehicle, use a jumper wire and connect a 12 volt supply to Pin 1 and 2. Using a third jumper wire, ground Pin 3. Refer to and the Rear Window Defogger Switch and Harness Connector Pin Call-Outs table. 3. Follow the same procedures used for IN-VEHICLE TESTING, except for step Step 2. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door (Driver) - RHD Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7823 Door (Passenger) - LHD Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7824 Power Window Switch: Diagrams Driver Power Window Switch C1 Driver Power Window Switch C2 Passenger Power Window Switch (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7825 Passenger Power Window Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7826 Power Window Switch: Testing and Inspection Power Window Switch Continuity Remove the switch from its mounting, (Refer to POWER WINDOWS/POWER WINDOW SWITCH REMOVAL). Using an ohmmeter, test the window switch for continuity in all positions Refer to Power Window Switch Continuity table to determine if continuity is correct. If the correct results are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7827 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on window switch bezel and remove from door trim panel. 3. Disconnect wire connector from switch. 4. Remove two switch retaining screws. INSTALLATION 1. install the switch retaining screws. 2. Reconnect the wire connector to the switch. 3. Insert switch into the door trim panel. 4. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Move the window to the full-up position, if possible. 3. Remove front door trim panel. 4. Remove front door water shield. 5. Remove three screws to front door radio speaker so that motor has room to pivot. 6. Pivot window motor out of door panel. 7. Remove three motor retaining screws to drive cable. 8. Remove motor from drive cable assembly. INSTALLATION 1. Install motor to the cable drive assembly. 2. Install motor retaining screws to drive cable. 3. Install the screws to the front door radio speaker. 4. Install the front door water shield. 5. Install the front door trim panel. 6. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door (Driver) - RHD Door (Driver) - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7836 Door (Passenger) - LHD Door (Passenger) - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7837 Power Window Switch: Diagrams Driver Power Window Switch C1 Driver Power Window Switch C2 Passenger Power Window Switch (LHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7838 Passenger Power Window Switch (RHD) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7839 Power Window Switch: Testing and Inspection Power Window Switch Continuity Remove the switch from its mounting, (Refer to POWER WINDOWS/POWER WINDOW SWITCH REMOVAL). Using an ohmmeter, test the window switch for continuity in all positions Refer to Power Window Switch Continuity table to determine if continuity is correct. If the correct results are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7840 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on window switch bezel and remove from door trim panel. 3. Disconnect wire connector from switch. 4. Remove two switch retaining screws. INSTALLATION 1. install the switch retaining screws. 2. Reconnect the wire connector to the switch. 3. Insert switch into the door trim panel. 4. Reconnect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair BACKLITE WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. BE SURE TO DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. CAUTION: Open the left front door glass before installing the rear window to avoid pressurizing the passenger compartment if a door is slammed before the urethane bonding is fully cured. Water leaks can result. Refer to the windshield paragraph for a description of tools and adhesive systems that are recommended for use in this procedure. REMOVAL 1. Remove rear window moldings. 2. Remove upper quarter trim panel. 3. Disconnect wire connectors from rear window defogger. WARNING: WEAR EYE AND HAND PROTECTION WHEN HANDLING SAFETY GLASS. PERSONAL INJURY CAN RESULT. CAUTION: Do not damage body or trim finish when cutting out glass or applying fence primer. 4. Cut the urethane around the perimeter of the rear window glass. 5. Remove the rear window from the vehicle. INSTALLATION 1. Prepare the work area, window fence, and glass the same way as described in the Windshield. Fig. 1 2. Place fence spacers at the locations shown (Fig. 1). 3. Install the rear window molding on glass. 4. Apply a 10 mm (0.4 in.) bead of urethane around the perimeter of the glass. 5. Install the glass in the same manner described in the Windshield (Fig. 1). 6. Connect rear window defogger wiring and interior trim. 7. After urethane has cured, water test rear window to verify repair. Verify rear window defogger operation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar Front Door Window Glass Weatherstrip: Service and Repair Front Vertical Guide Bar FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7850 Front Door Window Glass Weatherstrip: Service and Repair B-Pillar Weatherstrip Channel B-PILLAR WEATHERSTRIP CHANNEL REMOVAL 1. Remove b-pillar applique. 2. Remove push in fasteners attaching weatherstrip to b-pillar. 3. Pull weatherstrip from b-pillar channels. 4. Remove screws attaching channels to b-pillar. 5. Remove channels from b-pillar. INSTALLATION 1. Install channels from b-pillar. 2. Install screws attaching channels to b-pillar. 3. Install weatherstrip to b-pillar channels. 4. Install push in fasteners attaching weatherstrip to b-pillar. 5. Install b-pillar applique. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7851 Front Door Window Glass Weatherstrip: Service and Repair FDR Glass Run Weatherstrip FDR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove flag cover, door trim panel, water dam as necessary. 2. Remove door glass. 3. Loosen side view mirror, as necessary. 4. Remove weatherstrip fasteners. 5. Pull weatherstrip from lower front channel above door latch. Fig. 1 6. Pull run weatherstrip from window frame channel (Fig. 1). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Tighten side view mirror. 8. Install pull cup support bracket, water shield, door trim panel and flag trim. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7852 Front Door Window Glass Weatherstrip: Service and Repair Outer Belt Weatherstrip OUTER BELT WEATHERSTRIP REMOVAL 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Fig. 2 3. Remove outer belt weatherstrip from vehicle (Fig. 2). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7853 Front Door Window Glass Weatherstrip: Service and Repair Front Vertical Guide Bar FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. B-Pillar Weatherstrip Channel B-PILLAR WEATHERSTRIP CHANNEL REMOVAL 1. Remove b-pillar applique. 2. Remove push in fasteners attaching weatherstrip to b-pillar. 3. Pull weatherstrip from b-pillar channels. 4. Remove screws attaching channels to b-pillar. 5. Remove channels from b-pillar. INSTALLATION 1. Install channels from b-pillar. 2. Install screws attaching channels to b-pillar. 3. Install weatherstrip to b-pillar channels. 4. Install push in fasteners attaching weatherstrip to b-pillar. 5. Install b-pillar applique. FDR Glass Run Weatherstrip FDR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove flag cover, door trim panel, water dam as necessary. 2. Remove door glass. 3. Loosen side view mirror, as necessary. 4. Remove weatherstrip fasteners. 5. Pull weatherstrip from lower front channel above door latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7854 Fig. 1 6. Pull run weatherstrip from window frame channel (Fig. 1). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Tighten side view mirror. 8. Install pull cup support bracket, water shield, door trim panel and flag trim. Outer Belt Weatherstrip OUTER BELT WEATHERSTRIP REMOVAL 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7855 Fig. 2 3. Remove outer belt weatherstrip from vehicle (Fig. 2). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Door Upper Secondary Weatherstrip DOOR UPPER SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Vertical Guide Bar > Page 7856 Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7862 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door trim panel, water dam as necessary. 2. Remove door glass. 3. Remove weatherstrip fasteners. 4. Pull weatherstrip from lower front channel above door latch. Fig. 4 5. Pull run weatherstrip from window frame channel (Fig. 4). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Install pull cup support bracket, water shield, and door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7863 Rear Door Window Glass Weatherstrip: Service and Repair RDR Secondary Weatherstrip RDR SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool C-4829 or equivalent, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7864 Rear Door Window Glass Weatherstrip: Service and Repair Roof Rail Weatherstrip ROOF RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. 2. Using a door trim removing tool, disengage the push-in fasteners holding A-pillar and C-pillar weatherstrip molding. 3. Starting at the bottom of the A-pillar, pull the roof rail weatherstrip from the windshield side molding. Fig. 5 4. Pull roof rail weatherstrip from the roof rail pinch flange above the door opening (Fig. 5). 5. Separate roof rail weatherstrip from vehicle. INSTALLATION 1. Place weatherstrip in position on pinch flange. 2. Starting at the bottom of the C-pillar, install the roof rail weatherstrip molding to the pinch rail. 3. Install push-in fasteners to hold weatherstrip to A-pillar and C-pillar. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7865 Rear Door Window Glass Weatherstrip: Service and Repair Front/Rear Door Inner Belt Weatherstrip FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 3 2. Remove weatherstrip from door. Use a rubber mallet and a block of wood, tap upward at each clip holding the molding to the door (Fig. 3). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door trim panel, water dam as necessary. 2. Remove door glass. 3. Remove weatherstrip fasteners. 4. Pull weatherstrip from lower front channel above door latch. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7866 Fig. 4 5. Pull run weatherstrip from window frame channel (Fig. 4). INSTALLATION 1. Clean butyl material from door flange area. 2. Place door run weatherstrip in position on window frame channel. 3. Push door run weatherstrip into window frame channel. 4. Push weatherstrip into lower front channel above door latch. 5. Install weatherstrip fasteners. 6. Install door glass. 7. Install pull cup support bracket, water shield, and door trim panel. RDR Secondary Weatherstrip RDR SECONDARY WEATHERSTRIP REMOVAL 1. Using a fork-type prying tool C-4829 or equivalent, disengage push in fasteners attaching door upper secondary weatherstrip to door opening. 2. Remove weatherstrip from door. INSTALLATION 1. Position weatherstrip to opening door. 2. Press door upper secondary weatherstrip fasteners into position. Roof Rail Weatherstrip ROOF RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. 2. Using a door trim removing tool, disengage the push-in fasteners holding A-pillar and C-pillar weatherstrip molding. 3. Starting at the bottom of the A-pillar, pull the roof rail weatherstrip from the windshield side molding. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7867 Fig. 5 4. Pull roof rail weatherstrip from the roof rail pinch flange above the door opening (Fig. 5). 5. Separate roof rail weatherstrip from vehicle. INSTALLATION 1. Place weatherstrip in position on pinch flange. 2. Starting at the bottom of the C-pillar, install the roof rail weatherstrip molding to the pinch rail. 3. Install push-in fasteners to hold weatherstrip to A-pillar and C-pillar. Roof Rail Weatherstrip Retainer Channel ROOF RAIL WEATHERSTRIP RETAINER CHANNEL REMOVAL 1. Open door(s). 2. Using trim stick disconnect 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, ensure all of the old two sided tape is removed from the vehicle surface before installation of new part. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7868 Fig. 6 3. Remove weatherstrip from the retainer channel (Fig. 6). 4. Remove retainer channel from the body side aperture. INSTALLATION 1. Install retainer channel to the body side aperture. 2. Remove weatherstrip from the retainer channel. 3. Connect the top and bottom push in fasteners to B-pillar applique. Gently push on the applique to install from the vehicle. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL Fig. 7 1. Using a fork-type prying tool, disengage push in fasteners attaching sill secondary weatherstrip to door (Fig. 7). 2. Remove weatherstrip from door. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 7869 INSTALLATION 1. Position weatherstrip to door. 2. Press sill secondary weatherstrip fasteners into position. Trunk Opening Weatherstrip TRUNK OPENING WEATHERSTRIP REMOVAL 1. Open decklid. Fig. 8 2. Pull decklid weatherstrip form decklid opening fence (Fig. 8). 3. Remove weatherstrip from vehicle. INSTALLATION 1. Place decklid opening weatherstrip into position. 2. Press the weatherstrip onto the decklid opening fence. 3. Close decklid. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair Window Handle: Service and Repair WINDOW CRANK REMOVAL 1. Open door. Fig. 13 2. Slide a window crank removal tool behind the window crank to release crank handle lock clip (Fig. 13). 3. Remove handle from regulator shaft. INSTALLATION 1. Place the lock clip on the window crank. 2. Place window crank on regulator shaft with the window in the down position. 3. Orientate the window regulator crank handle appropriately at the 10 o'clock position and the left handle at the 2 o'clock position. 4. Push the handle in to the lock position on the regulator shaft. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove door glass from regulator channel. Tie Strap Door Regulator Cable 3. Cut away the tie strap from the outboard regulator cable. Rear Door Glass 4. Loosen screws attaching window regulator channel and crank housing to door panel. 5. Disengage screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching window regulator to door panel. 7. Disengage regulator from door panel, and crank housing. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel, Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 7877 9. Remove window regulator from door through access hole in inner panel. INSTALLATION 1. Position window regulator and crank housing on door panel through access hole in door panel. 2. Tighten bolts attaching window regulator to door panel. 3. Engage window regulator bolt heads on channel to key hole slots in door panel. 4. Tighten screw attaching window regulator channel and crank housing. 5. Install a new tie strap around the outboard regulator cable and door inner sheet metal. 6. Position glass to regulator roller channel. 7. Tighten fasteners attaching door glass to roller channel. 8. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair FRONT VERTICAL GUIDE BAR REMOVAL 1. Remove door trim panel and water dam. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt attaching top of front guide bar to inner door panel. 5. Using a Snap-on(R) flare-nut socket (FRXM10) and a hex wrench, remove nut attaching bottom of guide bar to door panel while holding jack screws. INSTALLATION 1. Install nut attaching bottom of guide bar to door panel. 2. Install bolt attaching top of front guide bar to inner door panel. 3. Install front lift guide. 4. Install door speaker, if equipped. 5. Verify door glass alignment, adjust if necessary. 6. Install door trim panel and water dam. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions Windshield: Service Precautions STATIONARY GLASS DESCRIPTION SAFETY PRECAUTIONS WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED. CHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. BE SURE TO DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA. SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the moldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and moldings from the parts supplier. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7884 Windshield: Service and Repair WINDSHIELD DESCRIPTION The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. POWER KNIFE The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. RECOMMENDED TOOLS AND ADHESIVE - Fein(R) Power Cutout Knife - Equalizer(R) Magnum, Interior Auto Glass Cut Out Knife ADHESIVE, PRIMER AND CLEANER The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. RECOMMENDED TOOLS AND ADHESIVE The following urethane adhesive systems are OEM certified and conform to the FMVSS 212 windshield retention standard and the FMVSS 216 roof crush standard. REMOVAL EXTERIOR METHOD The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. 1. Remove inside rear view mirror. 2. Remove windshield wiper arms. 3. Remove cowl cover. 4. Place protective covers over instrument panel and hood. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7885 Fig. 2 5. Remove the screws and remove the windshield A-pillar moldings. (Fig. 2) Fig. 3 6. Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences (Fig. 3). A power cutting device can be used if available. 7. Separate windshield from vehicle. INTERIOR METHOD The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. 1. Remove inside rear view mirror. 2. Remove instrument panel top cover, refer to Instrument Panel. 3. Remove A-pillar trim covers. 4. Place protective covers over instrument panel and hood. 5. Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with the equipment being used. 6. Remove windshield from vehicle. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7886 INSTALLATION CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening. 1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. 2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. 3. Remove replacement windshield from windshield opening. Fig. 4 4. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4). WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. 5. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. 6. Apply molding to Top of windshield. 7. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible. 8. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time. 9. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence. 10. Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. 11. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence. 12. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7887 Fig. 5 13. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward molding is flush to roof line and A-pillars (Fig. 5). 14. Clean access urethane from exterior with Mopar(R), Super Clean or equivalent. 15. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 16. Install A-pillar moldings. 17. Install cowl cover and wipers. 18. Install inside rear view mirror. 19. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair Wiper Control Module: Service and Repair REMOVAL Fig.13 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove wiper arms. Refer to Electrical, Wipers/Washers, Wiper Arm, Removal. 3. Remove the left side cowl cover. Refer to Body Exterior, Cowl Cover, Removal. 4. Disconnect the motor posi-lock harness connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Page 7893 Fig.14 Wiper Module Remove/Install 5. Remove the wiper module mounting screws and remove the module from vehicle. INSTALLATION 1. Install the windshield wiper module into the vehicle. 2. Install the mounting screws and tighten to 7 - 9 Nm (60 - 80 in. lbs.) torque. 3. Connect the motor posi-lock harness connector. 4. Install the left side cowl cover. Refer to Body, Exterior, Cowl Cover, Installation. 5. Install the wiper arms. Refer to Electrical, Wipers/Washers, Wiper Arm, Installation. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Wiper/Washer Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 7898 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Replacement Fig.15 Wiper/Washer Switch REMOVAL 1. Remove the Multi-Function Switch from the vehicle Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 2. Remove the two retaining screws to the Wiper/Washer Switch. 3. Separate the two switches. INSTALLATION 1. Attach the two switches. 2. Install the two retaining screws to the Wiper/ Washer Switch. 3. Install the Multi-Function Switch from the vehicle. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7902 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7903 Wiper/Washer Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7904 Wiper Switch: Service and Repair Fig.15 Wiper/Washer Switch REMOVAL 1. Remove the Multi-Function Switch from the vehicle Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 2. Remove the two retaining screws to the Wiper/Washer Switch. 3. Separate the two switches. INSTALLATION 1. Attach the two switches. 2. Install the two retaining screws to the Wiper/ Washer Switch. 3. Install the Multi-Function Switch from the vehicle. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid > Component Information > Specifications Washer Fluid: Specifications Fill the reservoir with windshield washer solvent. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair Fig.6 Washer Hose REMOVAL For damaged or plugged washer hose, remove the effected piece of hose and replace, routing hose the same way as removed. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Service and Repair Windshield Washer Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect the wire connector from the reservoir pump. 4. Disconnect the washer hose at the pump and drain the reservoir. 5. Gently pry pump away from reservoir and out of grommet. Care must be taken not to puncture reservoir. 6. Remove rubber grommet from reservoir. If replacing the pump, discard the old washer pump grommet. If replacing the reservoir only, reuse the old washer pump grommet. INSTALLATION NOTE: Make sure to use new grommet when installing new washer pump. 1. Install the rubber grommet into the reservoir. If replacing the pump, discard the old washer pump grommet. If replacing the reservoir only, reuse the old washer pump grommet. 2. Position pump in hole and firmly snap into the grommet. Care must be taken not to puncture reservoir. 3. Connect the washer hose at the pump and fill the reservoir. 4. Connect the wire connector to the reservoir pump 5. Lower vehicle from hoist 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Pump Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 7917 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect the wire connector from the reservoir pump. 4. Disconnect the washer hose at the pump and drain the reservoir. 5. Gently pry pump away from reservoir and out of grommet. Care must be taken not to puncture reservoir. 6. Remove rubber grommet from reservoir. If replacing the pump, discard the old washer pump grommet. If replacing the reservoir only, reuse the old washer pump grommet. INSTALLATION NOTE: Make sure to use new grommet when installing new washer pump. 1. Install the rubber grommet into the reservoir. If replacing the pump, discard the old washer pump grommet. If replacing the reservoir only, reuse the old washer pump grommet. 2. Position pump in hole and firmly snap into the grommet. Care must be taken not to puncture reservoir. 3. Connect the washer hose at the pump and fill the reservoir. 4. Connect the wire connector to the reservoir pump 5. Lower vehicle from hoist 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable 2. Raise vehicle on hoist 3. Disconnect the wire connector from the reservoir pump. 4. Disconnect the washer hose at the pump and drain the reservoir. 5. Remove three fasteners from reservoir. 6. Remove the reservoir through fender opening. 7. Remove the windshield washer pump from the reservoir (Refer to WIPERS/ WASHERS/WASHER PUMP MOTOR - REMOVAL). INSTALLATION 1. Install the windshield washer pump into the reservoir (Refer to WIPERS/ WASHERS/WASHER PUMP MOTOR - INSTALLATION). 2. Install the reservoir through fender opening. 3. Install the fasteners to the reservoir. Tighten the reservoir screws to 6.8 - 8.5 Nm (60 - 75 in. lbs.) torque. 4. Connect the washer hose at the pump and fill the reservoir. 5. Connect the wire connector to the reservoir pump 6. Lower vehicle from hoist. 7. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations Windshield Washer Spray Nozzle: Locations Fig.7 Windshield Washer Nozzle There are two hood mounted washer nozzles Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations > Page 7924 Windshield Washer Spray Nozzle: Description and Operation Fig.7 Windshield Washer Nozzle There are two hood mounted washer nozzles. The right and left nozzles have different aims, but can be installed in either hood hole and aimed appropriately. Fig.8 Windshield Washer Pattern - Typical Each nozzle emits two streams into the wiper pattern . If the nozzle performance is unsatisfactory they can be adjusted. To adjust front washer nozzle(s): - Insert a pin into the nozzle ball and move so that it sprays into the proper pattern area. NOTE: Aim the spray towards the top of the pattern area. When proceeding down the road at speed, the spray will hit the windshield lower than when the vehicle is at rest. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations > Page 7925 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Open hood. 2. Disconnect the washer hose from the underside of the washer nozzle. 3. Using a plastic body filler spreader or equivalent (credit card), gently place it underneath the front of the washer nozzle. Be careful not to damage the hood seal underneath the nozzle. 4. Rock the nozzle back and forth slightly to release it from the hood panel. INSTALLATION 1. Position nozzle over hole in hood panel and firmly snap into place. Make sure the seal is present and not damaged. 2. Connect hose to nozzle on underside of hood. 3. After connecting hose, check for proper system function and to assure leak free connections by actuating the washer system switch from inside of vehicle. Verify nozzle aim and adjust as necessary. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Wiper/Washer Switch Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 7929 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Replacement Fig.15 Wiper/Washer Switch REMOVAL 1. Remove the Multi-Function Switch from the vehicle Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 2. Remove the two retaining screws to the Wiper/Washer Switch. 3. Separate the two switches. INSTALLATION 1. Attach the two switches. 2. Install the two retaining screws to the Wiper/ Washer Switch. 3. Install the Multi-Function Switch from the vehicle. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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. Windshield Wiper Blade/Arm Park Lines 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 7933 Wiper Arm: Service and Repair REMOVAL 1. Place the wiper arm/blades in the PARK position and turn ignition OFF 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry up on arm cap and remove. 3. Remove the wiper arm retaining nut. 4. Remove the arm from the pivot using a rocking motion while the arm is in an over/centered position. 5. Clean metal splinters OFF the pivot shafts. INSTALLATION Ensure the wiper module is in the PARK position (cycle motor if necessary). Position wiper arms so that the heel of the blade(s) is on the park line on the windshield. Refer to Electrical, Wipers/Washers, Wiper Arms, Adjustments. for wiper arm adjustment. 1. Clean metal splinters OFF the pivot shafts. 2. Install the arm onto the pivot using a rocking motion while the arm is in an over/centered position. 3. Install the wiper arm retaining nut. Torque nut to 19.7 - 21.5 Nm (175 190 in. lbs.). 4. Install the arm nut cap. 5. Cycle the Place the wiper arm/blades, and verify that they end up in the PARK position and turn ignition OFF. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) 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 (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7947 Wiper Blade: Locations The wiper blades are a rubber element with a steel vertebra that are mounted on the end of the windshield wiper arm and sweep across the front windshield to clear it of water, snow, and debris. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7948 Wiper Blade: Description and Operation The wiper blades are a rubber element with a steel vertebra that are mounted on the end of the windshield wiper arm and sweep across the front windshield to clear it of water, snow, and debris. When the wiper blade rubber element is exposed to the weather for a long period of time, it tends to lose wiping ability Periodic cleaning of the wiper blade element is suggested to remove the accumulation of salt and road film. The wiper blades, arms, and windshield should be cleaned with washer fluid , a sponge or cloth and a mild detergent, or non-abrasive cleaner. If the blades continue to streak or smear, they should be replaced. The driver blade element is 550 mm in length and the passenger blade element is 475 mm in length. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement Wiper Blade: Service and Repair Wiper Blade Replacement REMOVAL 1. Lift wiper arm to the over center position. Wiper Blade And Element 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 1. Gently lift wiper arm tip off glass surface and to the over center position. Wiper Blade And Element 2. Install the blade assembly onto the arm by sliding blade towards arm tip. 3. Lower the wiper arm to the glass surface and check the wiping pattern. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement > Page 7951 Wiper Blade: Service and Repair Wiper Blade Element Replacement REMOVAL 1. Lift wiper arm to raise blade off glass. Wiper Blade And Element 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 vertebrae (metal rails). INSTALLATION 1. Install the wiping element onto the blade assembly. Push into the end of the blade assembly by pressing the claw together with vertebrae (metal rails) . 2. Install the blade assembly onto the arm by sliding onto the arm tip. Gently place wiper arm tip on glass surface. Check that the element and vertebrae are through all claws and the final claw is locked in the stopper. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair Wiper Control Module: Service and Repair REMOVAL Fig.13 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove wiper arms. Refer to Electrical, Wipers/Washers, Wiper Arm, Removal. 3. Remove the left side cowl cover. Refer to Body Exterior, Cowl Cover, Removal. 4. Disconnect the motor posi-lock harness connector. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Page 7955 Fig.14 Wiper Module Remove/Install 5. Remove the wiper module mounting screws and remove the module from vehicle. INSTALLATION 1. Install the windshield wiper module into the vehicle. 2. Install the mounting screws and tighten to 7 - 9 Nm (60 - 80 in. lbs.) torque. 3. Connect the motor posi-lock harness connector. 4. Install the left side cowl cover. Refer to Body, Exterior, Cowl Cover, Installation. 5. Install the wiper arms. Refer to Electrical, Wipers/Washers, Wiper Arm, Installation. 6. Connect the battery negative cable. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Wiper Motor Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7960 Wiper Motor: Testing and Inspection Wiper Motor Diagnosis ( Part 1 Of 2 ) Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7961 Wiper Motor Diagnosis ( Part 2 Of 2 ) Whenever a wiper motor malfunction occurs, verify that the wire harness is properly connected, then start normal diagnosis and repair procedures. Refer to the WIPER MOTOR DIAGNOSIS table. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7962 Wiper Motor: Service and Repair REMOVAL 1. Remove wiper module (Refer to WIPERS/WASHERS/WIPER MODULE - REMOVAL). 2. Remove linkage from motor crank. Insert screwdriver or equivalent between crank and linkage then twist and lift straight up on linkage. 3. Remove three motor mounting screws and separate motor from linkage. INSTALLATION 1. Attach motor to module. Install the three motor mounting screws and tighten the motor mounting screws to 5 - 6 Nm (45 - 55 in. lbs.) torque. NOTE: - If motor crank was taken off for any reason, install and tighten drive link nut to 11 - 12 Nm (98 106 in. lbs.) torque. - Make sure motor is parked before attaching the wiper arms. 2. Add unilube grease to the linkage socket and install the linkage onto the motor crank. 3. Install the wiper module (Refer to WIPERS/WASHERS/WIPER MODULE - INSTALLATION). Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove wiper module Refer to Electrical, Wipers/Washers, Wiper Module Removal. 2. With the wiper module on the bench, disconnect wiper arm linkage by inserting a screwdriver or equivalent between ball cap and linkage. Twist and lift straight up on linkage. INSTALLATION 1. With the wiper module on the bench, connect wiper arm linkage by using pliers or your hand and press the ball cap straight on to the ball stud. 2. Install the wiper module. Refer to Electrical, Wipers/Washers, Wiper Module, Installation. Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Fig. 21 Instrument Panel - LHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7969 Fig. 51 Instrument Panel - RHD Dodge Neon Workshop Manual (L4-2.0L VIN F HO (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7970 Wiper/Washer Switch