Dodge - Neon R - Workshop Manual - 2001 - 2001

Factory Workshop Manual Make Dodge Model Neon R Engine and year R-T L4-2.0L VIN F HO (2001) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest: > 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest: > 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Wiring Harness: All Technical Service Bulletins Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 24 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 30 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 31 Alarm Module: Locations Sentry Key Immobilizer (SKIM) Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 32 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 33 Alarm Module: Description and Operation Sentry Key Immobilizer (SKIM) Location SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) (Fig.9) 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 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. Refer to Electrical, Vehicle Theft Security Transponder Key, Standard Procedure - Sentry Key Immobilizer System Transponder programming. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 34 Alarm Module: Testing and Inspection To Switch Operating Modes or to Configure A New Module, a DRBIII(R) scan tool must be used. Fig.10 Data Link Connector (DLC) Location 1. Hook up the DRBIII(R) scan tool to the Data Link Connector (DLC). 2. With the key in the ignition, turn the key to the RUN position. 3. After the DRBIII(R) scan tool initialization, perform the following: a. Select "Theft Alarm." b. Select "VTSS." c. Select "Miscellaneous," 4. Once in the "Miscellaneous" screen: a. If you wish to configure a new module, select "Configure Module." b. If you wish to put the module into customer usage mode, select "Enable VTSS." c. If you wish to put the module into dealer lot mode, select "Dealer Lot." Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 43 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 49 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 50 Keyless Entry Module: Locations Fig.3 RKE Module Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 51 Remote Keyless Entry Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 52 Keyless Entry Module: Description and Operation 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 53 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 54 Keyless Entry Module: Service and Repair REMOVAL Fig.1 Battery Negative Cable Remove/Install 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. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 55 NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 65 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 71 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 72 Keyless Entry Module: Locations Fig.3 RKE Module Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 73 Remote Keyless Entry Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 74 Keyless Entry Module: Description and Operation 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 75 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 76 Keyless Entry Module: Service and Repair REMOVAL Fig.1 Battery Negative Cable Remove/Install 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. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 77 NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Control Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 83 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 84 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations Controller Antilock Brake: Locations Fig.1 Integrated Control Unit (ICU) HCU Location The CAB is mounted to the bottom of the HCU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 89 Controller Antilock Brake: Diagrams Controller Antilock Brake Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 90 Controller Antilock Brake: Description and Operation Fig.1 Integrated Control Unit (ICU) CONTROLLER ANTILOCK BRAKE The controller antilock brake (CAB) is a microprocessor-based device which monitors the ABS system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: monitor the antilock brake system for proper operation. - detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction control system is activated. - store diagnostic information. - provide communication to the DRBIII scan tool while in diagnostic mode. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will send a message to the Mechanical Instrument Cluster (MIC) instructing it to turn ON the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning lamp is turned ON and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. These DTC's will remain in the CAB memory even after the ignition has been turned OFF. The DTC's can be read and cleared from the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles of vehicle operation. Controller Antilock Brake Inputs Wheel Speed sensors (four) - Brake Lamp switch - Ignition Switch - System Relay Voltage - Ground - Traction Control Lamp Actuation - Diagnostic Communication (PCI) Controller Antilock Brake Outputs Amber ABS warning indicator lamp actuation (through MIC) - Red BRAKE warning indicator lamp actuation (through MIC) - Traction control lamp - Diagnostic communication. (PCI) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 91 Controller Antilock Brake: Service and Repair REMOVAL To remove the CAB, the ICU must be removed from the vehicle and disassembled. INSTALLATION To install the CAB, it must be attached to the HCU, forming the ICU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 96 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Radiator Fan Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 97 Power Distribution Center Radiator Fan Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 102 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 103 Compressor Clutch Relay: Diagrams Power Distribution Center A/C Compressor Clutch Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 104 Power Distribution Center A/C Compressor Clutch Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 109 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 110 Horn Relay: Diagrams Power Distribution Center Horn Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 111 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, refer to Wiring Diagrams. 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 - 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.4 Horn Relay 5. Check relay for 70 to 75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 112 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.5 Power Distribution Center (PDC) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 118 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 119 Relay Box: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 120 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 121 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 124 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 125 Relay Box: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 126 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 127 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation, this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set making diagnosis of the original problem more difficult. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation Body Control Module: Description and Operation System Description and Functional Operation SYSTEM DESCRIPTION The body system on the 2001 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 of this general information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 135 Body Control Module: Description and Operation Functional Operation Part 1 of 2 FUNCTIONAL OPERATION 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 micro-processor 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. Driver Airbag Module (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. THE AIRBAG MODULE 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 136 Passenger Airbag Module (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. THE AIRBAG MODULE 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 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). 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 Airbag Modules 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. THE SEAT 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). 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. ACM/SIACM 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 137 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 minmum 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. AUDIO SYSTEM The audio system on the 2001 PL consists of a radio that communicates over the PCI bus. Each radio system comes equipped with a standard premium 6 speaker system. 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. Depending on the manufacture, some systems will have Front/Rear output system and others will have a Left/Right output system. 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 can display, indicating which output is effected. 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. Part 2 of 2 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) For the domestic market there are 2 (two) Instrument Cluster types, Base and Premium. The Premium Instrument Cluster is equipped with a Tachometer and a Low Fuel indicator. 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 to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 138 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. INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. The instrument cluster is sometimes referred to as a "Smart Cluster Control Module". 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. 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Vehicle Theft Security System The VTSS monitors the vehicle doors, decklid, hood and the ignition for unauthorized operation. Additionally, the decklid key cylinder is monitored for tampering, such as attempts to punch out the key cylinder. The alarm activates by sounding the horn, flashing the headlamps, park lamps and the VTSS indicator in the instrument cluster. Locking the doors with the door lock switch (through following a normal exit sequence of opening the door, pressing the lock button, and closing the door), the door cylinder lock switches or the RKE transmitter arms the system. During the 16 second arming process the VTSS indicator will flash quickly and when the system is armed will slow down. THE SYSTEM WILL NOT ARM IF THE HOOD IS OPEN (switch is grounded), or the decklid security switch (knockout) is not grounded, the LED will stay ON steady during arming. The engine kill feature on domestic vehicles is accomplished via the Sentry Key Immobilizer Module (SKIM). All of the sensors for the VTS 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. Power Door Locks Central Locking This feature allows the customer to lock/unlock all vehicle doors with the key from either front door cylinder lock switch. The customer can choose to program this feature to unlock all doors with one turn of the key or open the driver door only with the first turn of the key and open the other doors with the second turn. Altering the operation of the unlock function via the key cylinder switch from one turn to two turns will also alter the operation of the RKE transmitter from one press to two presses. Rolling (Automatic) Door Locks All vehicle doors are locked automatically once the vehicle reaches a speed of 15 mph and all doors are closed. This feature can be also be enabled! disabled by the customer. Door Lock Inhibit This feature disables the door lock command from the interior door lock switch whenever the driver door is open and the key is in the ignition. This prevents the driver from locking the keys in the ignition when using the power door locks. This feature is inoperable if the IOD fuse is not installed. Power Decklid Release Electrically releases the decklid upon two presses of the RKE transmitter decklid release button. This feature is disabled once the speed of the vehicle is greater than 5 mph. This feature may be altered with the DRB III to allow the decklid to be released with one press of the RKE transmitter decklid release button. The decklid can also be released from the switch in the glove box. Panic Mode Upon activation of the panic function, the headlamps and park lamps flash in an alternating manner, the horn pulses every second and the courtesy lamps are turned ON. The panic mode allow normal nighttime driving by allowing the headlamps and park lamps to be on steady when the headlamp switch is in the ON position. Panic mode is activated immediately by pressing the panic button once. It does not disarm the VTSS or unlock the doors. It is canceled by pressing the button a second time, reaching a vehicle speed greater than 15 mph or after 3 minutes has elapsed in panic mode. Once panic mode has been activated there is a 2-second delay before it will turn OFF. Once it is cancelled there is a 2-second delay before it can be reactivated. This is to avoid the problem of deactivating and immediate reactivating due to multiple Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 139 button presses. 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 and is violet with a yellow tracer. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2001 PL: Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio - CD Changer - Remote Keyless Entry Module - Sentry Key Immobilizer Module - Transmission Control 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 140 are transmitting and is pulled up to about seven and a half volts when modules are transmitting. 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 12V 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 figure 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 module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 141 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 +/- 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle 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. 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Component Tests and General Diagnostics > Page 144 Body Control Module: Scan Tool Testing and Procedures 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Component Tests and General Diagnostics > Page 145 Down or Page Up function to display the information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 146 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Test Light Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure Powertrain Control Module: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 151 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 152 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 153 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 154 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws ................................................................................................................................4 Nm (35 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 155 Powertrain Control Module: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 158 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 159 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 160 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 161 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 162 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 163 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 164 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 166 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 167 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 168 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 169 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 170 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 171 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Powertrain Control Module: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 173 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 174 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams 2000 PL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 181 Powertrain Control Module: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 182 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 183 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 187 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 188 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 189 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 190 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 191 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 192 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Fuel Pump Relay: Locations Power Distribution Center The fuel pump relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 197 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 198 Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 199 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 also protects the power circuit for the Automatic Shutdown (ASD) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 203 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 204 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 205 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 206 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 207 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 208 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 212 Manifold Tuning Valve Relay: Diagrams Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 213 Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Airbag Control Module Air Bag Control Module: Locations Airbag Control Module The Airbag Control Module (ACM) is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Airbag Control Module > Page 219 Air Bag Control Module: Locations Side Impact Airbag Control Module (SIACM) Fig.24 Side Impact Airbag Control Module (SIACM) Location 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 220 Air Bag Control Module: Diagrams Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Airbag Control Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 221 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. - THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) Air Bag Control Module: Description and Operation Airbag Control Module (ACM) Fig.3 Airbag Control Module (ACM) Location AIRBAG CONTROL MODULE The Airbag Control Module (ACM) contains the sensing element, safing sensor, and energy reserve capacitor. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. 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 warning equipment is tested for 6 - 8 seconds every time the vehicle is started and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. 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 micro- processor 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 224 Air Bag Control Module: Description and Operation Side Impact Airbag Control Module (SIACM) Fig.24 Side Impact Airbag Control Module (SIACM) Location SIDE IMPACT AIRBAG CONTROL MODULES 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 airbag. 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 circuit 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. SEAT AIRBAG MODULES 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. THE SEAT 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). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 227 AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 228 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.19 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. 5. Remove the seat belt retractor. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 229 Fig.24 Side Impact Airbag Control Module (SIACM) Location 6. Remove the SIACM retaining nuts and ground eyelet. 7. Pull SIACM out of B-pillar. Fig.25 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 230 3. Install the seat belt retractor. 4. Install the lower B-pillar trim. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 235 8w-10-3 The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 236 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 237 Power Distribution Center Engine Starter Motor Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 238 Starter Relay: Service Precautions WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 239 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 240 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Starter Relay Pinout Starter Relay Pinout Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is. connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the ON position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 241 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the transmission range sensor only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the transmission range sensor and repair. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 242 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams Transmission Control Module: Diagrams Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 248 Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Diagrams Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 3. Remove the left side cowl cover. Refer to Body, Exterior, Cowl Cover, Removal. 4. Disconnect the motor posi-lock harness connector. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Page 256 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 to 9 Nm (60 to 80 in. lbs.) torque. 3. Connect the motor posi-lock harness connector. 4. Install the left side cowl cover. 5. Install the wiper arms. 6. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative remote cable. 3. Using a trim stick (special tool #C-4755) or equivalent, gently pry switch up and out of mounting bracket. 4. Disconnect wire harness connector from hood ajar switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch in vehicle. 2. Connect wire harness connector to hood ajar switch. 3. Firmly snap hood ajar switch into mounting bracket. 4. Connect the battery negative remote cable. 5. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 265 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch Passenger Cylinder Lock Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 266 Lock Cylinder Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative remote cable. 3. Using a trim stick (special tool #C-4755) or equivalent, gently pry switch up and out of mounting bracket. 4. Disconnect wire harness connector from hood ajar switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch in vehicle. 2. Connect wire harness connector to hood ajar switch. 3. Firmly snap hood ajar switch into mounting bracket. 4. Connect the battery negative remote cable. 5. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 275 Power Door Lock Switch: Testing and Inspection 1. Remove the switch from its mounting location, and disconnect from vehicle wiring harness. Door Lock Switch Resistance 2. Using an ohmmeter, refer to the table to determine if switch resistance is correct in the Lock and Unlock switch positions. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 276 Power Door Lock Switch: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Power Mirror Switch (LHD) Power Mirror Switch (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 280 Power Mirror Switch: Testing and Inspection 1. Remove power mirror switch. Mirror Switch Continuity (Part 1 Of 2) Mirror Switch Continuity (Part 2 Of 2) 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Continuity table 3. If test results are not obtained as shown in the Mirror Switch Continuity table, replace the switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 281 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 288 Sunroof / Moonroof Switch: Service and Repair CONTROL UNIT REMOVAL Fig. 1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 289 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 290 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 (Fig. 1). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations The Vehicle Theft Security System (VTSS) Deck Lid Security Switch is mounted to the back of the deck lid lock cylinder. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 294 Trunk / Liftgate Switch: Diagrams Decklid Release Switch (Power Release) Decklid Security Switch (Knock Out) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Decklid Release Switch Replacement Trunk / Liftgate Switch: Service and Repair Decklid Release Switch Replacement 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Decklid Release Switch Replacement > Page 297 Trunk / Liftgate Switch: Service and Repair Decklid Security Switch Replacement 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation For Description and Operation of this Component refer to Brakes, Description and Operation, System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 302 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 Service Precautions. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensor Head Mounting Bolt 105 in.lb Front Tone Wheel Clearance Minimum 0.011 in Maximum 0.056 in Rear Tone Wheel Clearance Minimum 0.018 in Maximum 0.044 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 311 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 312 Wheel Speed Sensor: Connector Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 313 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Front Wheel Speed Sensor Connector (Sensor Side) Left Rear Wheel Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 314 Left Rear Wheel Speed Sensor Connector (Sensor Side) Right Front Wheel Speed Sensor Right Front Wheel Speed Sensor Connector (Sensor Side) Right Rear Wheel Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 315 Right Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 316 Wheel Speed Sensor: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component, Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Service Precautions. 1. Raise the vehicle. 2. Disconnect the Wheel Speed Sensor (WSS) 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. Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. 4. Remove the bolt mounting the WSS 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. 5. Carefully, remove the sensor head from the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 319 6. Remove the screw securing the WSS to the rear of the strut. Remove the WSS. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 (WSS) to the strut using the its mounting screw. 2. Install the WSS 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 WSS 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. Lower the vehicle. 6. Road test vehicle to ensure proper operation of the base brakes and Antilock Brake System (ABS). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 320 Wheel Speed Sensor: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Disconnect the Wheel Speed Sensor (WSS) cable connector from the vehicle wiring harness. Remove the clip attaching WSS cable connector to the vehicle's body. 3. Remove the WSS 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 WSS cable routing bracket to rear strut. CAUTION: When removing a WSS 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 WSS to the rear disc brake adapter, then carefully remove the sensor head from the rear disc brake adapter and Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 321 vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 (WSS) head into the disc brake adapter. 2. Install the WSS mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. Install the WSS cable routing bracket on the rear strut. 4. Install WSS cable into the routing clips on the rear brake hose and brake tube. 5. Connect the WSS cable connector into vehicle wiring harness. Install the clip attaching the WSS cable connector to vehicle's body. 6. Lower the vehicle. 7. Road test the vehicle to ensure proper operation of the base brakes and Antilock Brake System (ABS). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 327 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 328 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 329 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 330 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations The speed control switches are mounted in two separate switch pods on the steering wheel and are wired through the clockspring device under the airbag module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 335 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. 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, TAPUP 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 COAST, and CANCEL. Refer to the Speed Control 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. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 336 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are 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. 1. Turn OFF ignition. 2. Remove two screws from side of each switch. 3. Rock switch away from airbag and steering wheel. 4. Disconnect two-way electrical connector. 5. Repeat for the other switch. INSTALLATION The speed control switches are 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. 1. Install switches. 2. Connect two-way electrical connector. 3. Install two screws to the side of each switch. 4. Install airbag, refer to the Restraint Systems Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 118). 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 PSI and 4 PSI. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure, within a maximum of 3 PSI of the switch's "Closed" circuit pressure point. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Page 341 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. 119). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 119). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator probe is located in the A/C housing and placed in the evaporator fins. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 349 Evaporator Temperature Sensor / Switch: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 350 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.12 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. Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2 °C to 7 °C (35 °F to 45 °F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 351 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 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.13 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 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 new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.6 High Pressure Cutout Switch Location The high pressure cut out switch is located on the rear of the compressor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 356 High Pressure Sensor / Switch: Service Precautions WARNING: - THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. - THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 357 High Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH Fig.6 High Pressure Cutout Switch Location 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 358 High Pressure Sensor / Switch: Service and Repair REMOVAL WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. 1. Recover refrigerant from A/C system. 2. Disconnect wiring connector at the switch. 3. Remove internal snap ring. 4. Pull switch out of compressor. INSTALLATION WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. 1. Clean any foreign matter from the switch mounting bore 2. Install the high pressure cutout switch with a new O-ring into the compressor. 3. Install the internal snap ring 4. Connect the wire harness to the switch. 5. Evacuate the refrigerant system. 6. Recharge the A/C system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.7 Expansion Valve And Low Pressure Cut-off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 362 Low Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH Fig.6 High Pressure Cutout Switch Location 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) A/C LOW PRESSURE SWITCH Fig.7 Expansion Valve And Low Pressure Cut-off Switch The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. The low pressure cut off switch is located on the expansion valve. The low pressure cut off switch turns OFF voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The low pressure cut Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 363 Low Pressure Sensor / Switch: Testing and Inspection The work area must not be below 21 °C (70 °F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kpa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 364 Low Pressure Sensor / Switch: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. 1. Recover A/C refrigerant. 2. Disconnect the wire connector at the cut off switch. Fig.7 Expansion Valve And Low Pressure Cut-off Switch 3. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. NOTE: Verify the O-ring condition on the replacement switch. 1. Using a sender unit socket, install the low pressure cutout switch into the expansion valve. 2. Connect the wire harness connector to the switch. 3. Evacuate the A/C refrigerant system. 4. Recharge the A/C system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 369 Door Switch: Diagrams Driver Door Ajar Switch Driver Door Lock Motor/Ajar Switch Hood Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 370 Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 374 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 375 Fuel Gauge Sender: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 376 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Back-Up Lamp Switch 18 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 381 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 backup 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. Tighter switch to 24 Nm (18 ft. lbs.) torque. CAUTION: Do not over tighten switch. 2. Connect back-up lamp switch connector. 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 385 Brake Lamp Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 386 Brake Light Switch: Description and Operation 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 is 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 387 Brake Light Switch: Testing and Inspection NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. If misadjusted, replace the switch. It cannot be readjusted. 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.1 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.2 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, do not reinstall it, replace the switch. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 388 Brake Light Switch: Service and Repair 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. Discard the brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. 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. 1. Mount and adjust the NEW brake lamp switch using the following procedure: a. Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. b. When the switch is fully seated in its bracket, rotate the switch clockwise approximately 300 to lock the switch into place. Fig.5 Adjustment Lever Movement c. With the brake pedal in the fully released position, move the lever on the back of the brake lamp switch from the angled non-adjusted position to the full vertical position as shown. This will adjust the brake lamp switch to the vehicle. 2. Reconnect the battery negative terminal. 3. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 4. Road test the vehicle to ensure proper operation of the brakes including ABS if equipped. and speed control if equipped. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Turn Signal And Hazard Warning Flasher Diagnosis (Part 1 Of 2) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 392 Turn Signal And Hazard Warning Flasher Diagnosis (Part 2 Of 2) FLASHER DIAGNOSIS Should any function of the multi-function switch fail, the entire switch assembly must be replaced. SWITCH DIAGNOSIS To test the switch: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 393 Fig.21 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shrouds. 3. Disconnect the switch connector. Fig.18 Combination Flasher Connector(A) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 394 Fig.19 Multi-Function Switch Connector (B) Fig.20 Windshield Wiper/Washer Switch Connector (C) Multi-Function Switch Continuity Test Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 395 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. Refer to,, and for connector terminal locations. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 396 Combination Switch: Service and Repair REMOVAL Fig.21 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove both upper and lower steering column shrouds. Fig.22 Multi-Function Switch Remove/Install 3. Disconnect both posi-lock harness connectors at the rear of the multi-function switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 397 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. Install both upper and lower steering column shrouds. 6. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 401 Door Switch: Diagrams Driver Door Ajar Switch Driver Door Lock Motor/Ajar Switch Hood Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 402 Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations The integrated switch assembly is mounted to the left hand side of the steering column. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 409 Multi-Function Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 410 Hazard Warning Switch: Description and Operation Fig.17 Multi-function Switch MULTI-FUNCTION SWITCH The turn signals are part of the multi-function switch, which contains: Electrical circuitry for turn signals. - Hazard warning switch. - Headlamp switch. - Fog Lamp Switch. - Headlamp beam select switch. - Optical Horn. - Instrument Panel Lamp Dimmer/Interior Lamp Switch. - Combination Flasher. Hazard Warning System The hazard warning system is actuated by a push button located in the multi-function switch on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on front of the button. The hazard warning system allows the vehicle operator to provide the drivers of other vehicles in near proximity an optical indication that the vehicle is disabled or is an obstacle to traffic flow. Unlike the turn signal system, the hazard warning system has battery current at all times, regardless of ignition switch position. When the hazard warning system is activated, the combination flasher will cause both the right and left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear turn signal lamps to flash ON and OFF. If the exterior lamps are turned OFF; the front park/turn signal lamps and the front side marker lamps will flash in unison. If the exterior lamps are turned ON, the front park/turn signal lamps and the side marker lamps will flash alternately. Multi-function Switch The integrated switch assembly is mounted to the left hand side of the steering column. When the driver wishes to signal his intentions to change direction of travel, he moves the lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position, a canceling cam molded to the clockspring mechanism comes in contact with the cancel actuator on the turn signal multi-function switch assembly. The cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Fig.17 Multi-function 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 414 Headlamp Leveling Switch (Built-Up-Export) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 415 Headlamp Switch: Description and Operation Fig.17 Multi-function Switch The headlamp switch is integral to the left stalk of the multi-function switch. located on the steering column behind the steering wheel. A knob on the end of the left control stalk controls all of the exterior lighting functions. Turn the end of the control lever to the first detent for parking light operation. Turn to the second detent for headlight operation. To activate the front fog lights, turn ON the parking lights or the low beam headlights and pull out the end of the control lever. The headlamp switch is part of the multi-function switch . Refer to Electrical, Lamps/Lighting Exterior, Multi-Function Switch, Diagnosis and Testing, The headlamp switch cannot be repaired. If found defective, it must be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 419 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 420 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 421 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 422 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 426 Turn Signal Switch: Description and Operation Fig.17 Multi-function Switch MULTI-FUNCTION SWITCH The turn signals are part of the multi-function switch, which contains: Electrical circuitry for turn signals. - Hazard warning switch. - Headlamp switch. - Fog Lamp Switch. - Headlamp beam select switch. - Optical Horn. - Instrument Panel Lamp Dimmer/Interior Lamp Switch. - Combination Flasher. Hazard Warning System The hazard warning system is actuated by a push button located in the multi-function switch on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on front of the button. The hazard warning system allows the vehicle operator to provide the drivers of other vehicles in near proximity an optical indication that the vehicle is disabled or is an obstacle to traffic flow. Unlike the turn signal system, the hazard warning system has battery current at all times, regardless of ignition switch position. When the hazard warning system is activated, the combination flasher will cause both the right and left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear turn signal lamps to flash ON and OFF. If the exterior lamps are turned OFF; the front park/turn signal lamps and the front side marker lamps will flash in unison. If the exterior lamps are turned ON, the front park/turn signal lamps and the side marker lamps will flash alternately. Multi-function Switch The integrated switch assembly is mounted to the left hand side of the steering column. When the driver wishes to signal his intentions to change direction of travel, he moves the lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position, a canceling cam molded to the clockspring mechanism comes in contact with the cancel actuator on the turn signal multi-function switch assembly. The cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 435 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 436 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 437 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 438 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 439 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 443 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 444 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 445 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 446 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 450 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 451 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 452 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 453 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 454 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 458 Fuel Level Sensor: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 459 Fuel Level Sensor: Service and Repair 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. 5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 460 Fig. 6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 7 Level Sensor 5. Slide level sensor wires through opening fuel pump module. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications Intake Air Temperature (IAT) Sensor: Specifications MAP/IAT Sensor Plastic Manifold......................................................................................................... ......................................................2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 464 Intake Air Temperature (IAT) Sensor: Locations Fig. 16 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 465 Inlet Air Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 466 Intake Air Temperature (IAT) Sensor: Description and Operation Fig. 16 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 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 470 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 471 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 472 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 473 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor ........................................................................................................................................ .................................................... 4.5 Nm (40 in. lbs) MAP/IAT Sensor (plastic manifold) .......................................................................................................................................................... 2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 477 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 478 Manifold Absolute Pressure Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 479 Manifold Absolute Pressure (MAP) Sensor: Description and Operation Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezoresistive 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 480 - Decel fuel shutoff 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 481 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 22 MAP Sensor REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 28 Nm (20 ft. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 26 Types Or O2 Sensors Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 490 Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Fig. 24 Downstream Heated Oxygen Sensor 1/2 The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 491 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 492 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 493 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 494 Oxygen Sensor: Description and Operation Fig. 26 Types Or O2 Sensors Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 495 Fig. 24 Downstream Heated Oxygen Sensor 1/2 Fig. 25 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. Separate controlled ground circuits are run through the PCM for the upstream O2 sensors. 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), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 496 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement Oxygen Sensor: Service and Repair Downstream 1/2 Replacement REMOVAL Fig. 28 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. 29 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 The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement > Page 499 2. Connect sensor electrical harness from clips along body. 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement > Page 500 Oxygen Sensor: Service and Repair Upstream 1/1 Replacement REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig. 27 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 504 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 505 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 506 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 507 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 511 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 512 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 513 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 514 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 518 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 519 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 520 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 521 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt ...................................................................................................................................................2.2 Nm (19.4 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 525 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 528 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 529 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 530 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 531 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 532 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 533 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 534 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 535 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 536 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 537 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 538 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 539 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 540 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 541 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 542 Vehicle Speed Sensor: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 543 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 544 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 545 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 546 Vehicle Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 Vehicle Speed Sensor: Service and Repair Manual Transmission A578 VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector. 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. 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. 2. Using a NEW O-ring, install the speed sensor to the transaxle. 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector. 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 > Page 549 Vehicle Speed Sensor: Service and Repair Automatic Transmission 31TH VEHICLE SPEED SENSOR/ PINION GEAR REMOVAL 1. Remove harness connector from sensor. Be sure weather seal stays on harness connector. 2. Remove bolt securing the sensor in the extension housing. 3. Carefully pull sensor and pinion gear assembly out of extension housing. 4. Remove pinion gear from sensor. 5. Inspect pinion gear for damage (missing teeth, etc.) and replace as necessary. NOTE: When removing vehicle speed sensor for any reason, a new O-ring MUST be used. INSTALLATION 1. Install vehicle speed sensor and pinion gear to extension housing with new O-ring. 2. Install bolt and torque to 7 Nm (60 inch lbs.). 3. Connect connector. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 554 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 555 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 556 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 557 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 562 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 563 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 564 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 565 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 566 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 570 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 571 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 572 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 573 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 574 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 583 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 584 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 585 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 586 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 592 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 593 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 594 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 595 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 596 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 597 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation DESCRIPTION The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 4). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 5), each switch being fastened by four plastic wing tabs. OPERATION CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch engaged and the transaxle in gear. The switch is open while the clutch pedal is at rest. When the clutch pedal is fully depressed, the pedal blade 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 605 Clutch Switch: Testing and Inspection CLUTCH INTERLOCK/UPSTOP SWITCH The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 6). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 7), each switch being fastened by four plastic wing tabs. 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.) and for proper installation of the master cylinder push rod/bushing on the pedal pin. Also make sure the clutch pedal blade contacts and fully closes the switch. 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 with the interlock switch not depressed (clutch pedal at rest). There should be Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 606 no continuity between the terminals (open circuit). 5. Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm. (0.050 inch). The ohmmeter should show continuity (0 ohms). 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. 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 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. CLUTCH INTERLOCK/UPSTOP SWITCH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 607 Clutch Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 8). 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. 9). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 608 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 10). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 10). 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. 10). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 11) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 609 1. Install switches into the pedal bracket assembly as shown in (Fig. 11). Route harness as was prior to removal. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 34 Nm (25 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. 9). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 6. Connect clutch master cylinder pushrod. Loosen adjustment screw (Fig. 12) and gently lift clutch pedal upwards until the clutch pedal fully depresses the the upstop switch. Torque adjustment screw to 8 Nm (70 inch lbs.). 7. Connect interlock/upstop and stop lamp switch connectors. 8. Install left lower instrument panel bezel (Fig. 8). 9. Connect battery negative cable. 10. Verify proper switch operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral 25 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 618 Neutral Safety Switch: Locations Park/Neutral Switch The 31TH Park/Neutral Position Switch is located on the automatic transaxle housing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 619 Park/Neutral Position Switch (ATX) 31TH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > 31TH Transmission Neutral Safety Switch: Description and Operation 31TH Transmission PARK/NEUTRAL POSITION SWITCH - PCM INPUT Park/Neutral Switch The 31TH park/neutral position switch is located on the automatic transaxle housing. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. The PCM delivers 8.5 volts to the center terminal of the Park/Neutral switch. When the gear shift lever is moved to either the Park or the Neutral position, the PCM receives a ground signal from the Park/Neutral switch. With the shift lever positioned in Drive or Reverse, the Park/Neutral switch contacts open, causing the signal to the PCM to go high. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > Page 622 Neutral Safety Switch: Testing and Inspection PARK/NEUTRAL STARTING AND BACK-UP LAMP SWITCH 31TH TEST The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > Page 623 Neutral Safety Switch: Service and Repair TEST The 31TH park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. REMOVAL 1. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 629 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 630 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 631 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 632 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 638 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 639 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 640 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 644 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 645 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 646 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 647 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations Rear Window Defogger Switch: Locations Rear Window Defogger Switch Location The rear window defogger switch is a control switch and timing circuit integrated into a single panel mounted assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 655 Rear Window Defogger Switch: Description and Operation Rear Window Defogger Switch Location The rear window defogger switch is a control switch and timing circuit integrated into a single panel mounted assembly. Actuating the switch energizes the circuit which allows current to flow through the grid lines. Upon initial actuation for approximately eight to ten minutes, or until either the switch or ignition is turned OFF. An indicating lamp illuminates a Light Emitting Diode (LED) inlaid in the control switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 656 Rear Window Defogger 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. 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 657 3. Follow the same procedures used for IN-VEHICLE TESTING, except for step Step 2. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Power Window Switch Continuity Remove the switch from its mounting, (Refer to ELECTRICAL/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 results are not obtained, replace the switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 661 Power Window Switch: Service and Repair Battery Negative Cable Remove/Install 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair REMOVAL 1. Remove the Multi-Function Switch from the vehicle. Fig.15 Wiper/washer Switch 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications CURB HEIGHT SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS NOTE: All specifications are given in degrees. NOTE: All wheel alignments are to be set with the vehicle at curb height. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 670 Alignment: Description and Operation DESCRIPTION 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. 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. 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 0.0°, the cross camber would be +0.3°. CASTER Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 671 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 672 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 673 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. Lee 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 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 674 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection STANDARD PROCEDURE - 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 tees 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 677 Alignment: Service and Repair Wheel Alignment Wheel Alignment Setup 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 Adjustment Bolt Package Installation 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 undersized allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersized bolts provide approximately two degrees 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. 2. Remove the wheel and tire assembly at the strut requiring modification. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 678 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 114 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. Camber and Caster Adjustment 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. Front Toe Adjustment 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 679 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. Rear Toe Adjustment 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 680 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 (66 ft. lbs.). 4. Proceed to FRONT TOE to set the front toe. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 681 Alignment: Service and Repair Curb Height Measurement STANDARD PROCEDURE - CURB HEIGHT 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 687 Fuel Pressure: Specifications Fuel System Volume Fuel System Volume Volume 1/4 Liter (1/2 pint) in 7 seconds Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 688 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 689 Tests 3 - 5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 690 Tests 6 - 10 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 pump capacity (volume) out of specs - Fuel pump relay fused B+ circuit - Fuel pump relay output circuit open Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 691 - Fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 600-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test, using a scan tool. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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. 9). 2. Install lid and tighten screws. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 703 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 708 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 709 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE.................................................................................................................................................. ............................................................RESISTANCE #1 #4..................................................................................................................................................... ............................................. 3500 ohms - 4900 ohms #2 #3..................................................................................................................................................... ............................................. 2950 ohms - 4100 ohms Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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(R) parts cleaner or equivalent. 2. Apply Mopar(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation > Page 724 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 728 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. Disconnect the ignition coil electrical connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 735 Timing Belt: Service and Repair REMOVAL 1. Remove the accessory drive belts. 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove the crankshaft damper. 4. Remove the lower torque strut. 5. Lower vehicle and place a jack under engine. 6. Remove the upper torque strut. 7. Remove the engine right mount to engine mount bracket through bolt. 8. Remove the power steering pump assembly and set aside. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 736 9. Remove the engine mount bracket (Fig. 164). 10. Remove the timing belt front cover (Fig. 165). CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft. 11. Rotate crankshaft until timing marks are aligned at both the camshaft and crankshaft. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 737 12. Loosen the timing belt tensioner fasteners (Fig. 166). CAUTION: DO NOT loosen, tighten, or remove the tensioner pivot bolt (Fig. 167). 13. 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. 14. For timing belt tensioner pulley assembly removal; refer to Timing Belt Tensioner; Service and Repair. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 738 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. 168). 2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover (Fig. 169). 3. Move crankshaft to 1/2 mark before TDC (Fig. 170) for belt installation. 4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket. 5. Move crankshaft sprocket to TDC to take up belt slack. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 739 6. Re-set the hydraulic tensioner by placing tensioner body in a vise equipped with soft jaws (Fig. 171). 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. 171). 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. 172). 11. Pull the tensioner plunger retaining pin. Pretension is correct when the pin can be removed and installed into tensioner housing and plunger. 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks (Fig. 170) and (Fig. 169). 13. Check belt tension by installing pin into tensioner housing. If pin cannot be re-installed, repeat belt tension procedure. 14. Install the timing belt front cover. 15. Install the engine mount bracket. 16. Install the engine right mount to engine mount bracket through bolt. 17. Remove jack from under engine. 18. Install the upper torque strut. 19. Install power steering pump assembly. 20. Raise vehicle and install lower torque strut. 21. Install the crankshaft damper. 22. Install accessory drive belts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 740 23. Install right inner splash shield. 24. Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows: - 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. - Turn the ignition switch on and access the "miscellaneous" screen. - Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION The accessory drive consist of two Poly-V type drive belts (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 744 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT DIAGNOSIS Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 745 Drive Belt: Service and Repair REMOVAL Power Steering Pump And Air Conditioning Compressor Belt 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 3) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 4). Generator Belt 1. Remove power steering pump/air conditioning compressor drive belt. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 746 2. Loosen pivot bolt, then locking nut and adjusting bolt (Fig. 5). 3. Remove generator belt. NOTE: When installing drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. 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). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 747 NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION Power Steering Pump And Air Conditioning Compressor Belt 1. Install the drive belt (Fig. 4) over all the pulleys except for the power steering pump pulley. 2. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 3) until belt can be installed on the power steering pulley. Release spring tension onto belt. 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. 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. Generator Belt 1. Install belt and/or adjust belt tension by tightening adjusting bolt. Adjust belt to specification shown in DRIVE BELT TENSION CHART. 2. Check belt tension using Special Tool 8371 Belt Tension Gauge Adapter, and the DRBIII using the following procedures: WARNING: DO NOT CHECK BELT TENSION WITH ENGINE RUNNING. a. Connect 8371 to the DRBIII following the instructions provided with tool. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 748 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 DRBIII screen. e. Adjust belt to obtain proper frequency (tension). Refer to DRIVE BELT TENSION CHART for specifications. 3. Tighten pivot bolt to 54 Nm (40 ft. lbs.) and locking nut to 54 Nm (40 ft. lbs.) (Fig. 5). 4. Install power steering pump and A/C compressor drive belt. DRIVE BELT TENSION CHART Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair 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. 9). 2. Install lid and tighten screws. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Screw, Fluid Filter 45 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 760 Fluid Filter - A/T: Service and Repair STANDARD PROCEDURE - FLUID AND FILTER CHANGE NOTE: For the recommended maintenance (fluid/filter change) intervals for this transaxle, (Refer to MAINTENANCE) NOTE: Only fluids of the type labeled Mopar(R) 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. NOTE: 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. Remove oil filter-to-valve body screws (Fig. 160). 4. Remove oil filter and gasket (Fig. 161). 5. Install a new filter and gasket (Fig. 161). 6. Clean the oil pan and magnet. Reinstall pan using new Mopar(R) Silicone Rubber Adhesive Sealant. Torque oil pan bolts to 19 Nm (165 inch lbs.). 7. Pour four quarts of Mopar(R) ATF +4 (Automatic Transmission Fluid-Type 9602) through the dipstick opening. 8. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 761 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick (Fig. 162). 10. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 11. 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 TM 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(R) 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 "ADD" mark on the dipstick (Fig. 162). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 766 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Fig. 22 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 22). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 15 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 773 Oil Filter: Service and Repair REMOVAL CAUTION: When servicing the oil filter (Fig. 114), 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. 114). 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. 114). Tighten to 21 Nm (15 ft. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Locations Refrigerant Filter: Locations The filter/drier is mounted in a rubber grommet on the right side of the engine compartment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Locations > Page 777 Refrigerant Filter: Service and Repair REMOVAL 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. 1. Evacuate and recover the refrigerant. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation > Page 782 Coolant Line/Hose: Service and Repair 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(R) Dielectric Grease and install inlet tube into the cylinder block opening. 3. Install inlet tube fasteners and tighten to 12 Nm (105 inch lbs.). 4. Install intake manifold lower support bracket fasteners and tighten to 12 Nm (105 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL 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. 1. Drain engine cooling system. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Fig.23 Heater Hoses And Clamps 2. Using spring tension clamp pliers, remove clamps at end of heater hose to be removed. 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 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. 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 788 Heater Hose: Service and Repair Heater Return Hose Replacement REMOVAL 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. 1. Drain engine cooling system. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Fig.24 Heater Hoses And Clamps 2. Using spring tension clamp pliers, 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. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 789 Heater Hose: Service and Repair Heater Tube Assembly Replacement REMOVAL 1. Disconnect negative battery cable. Disconnect positive battery cable. Remove battery. 2. Raise vehicle on hoist. 3. Drain cooling system . Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 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. 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. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 793 Hose/Line HVAC: Locations Fig.4 A/C Compressor Lines The suction line is the large line that connects to the expansion valve and goes to the compressor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Fig.4 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 796 Hose/Line HVAC: Description and Operation A/C Liquid Hose/Line Fig.4 A/C Compressor Lines 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 797 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line Fig.4 A/C Compressor Lines 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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 A/C system. Fig.5 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 800 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 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 WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 801 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement 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.27 Expansion Valve Center Bolt 2. Remove retaining bolt at expansion valve. 3. Remove line at expansion valve. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 802 Fig.28 A/C Compressor Suction Line 4. Remove line at 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Tube Nuts 25 ft.lb Hose Routing Clip Bolt 105 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 806 Power Steering Line/Hose: Description and Operation HOSES - DESCRIPTION The power steering fluid hoses connect the components of the power steering system. They transfer fluid from one component to the next. The power steering fluid pressure hose is a high pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting with an O-ring is used at each end to connect it to either the power steering pump or the gear. The power steering fluid return hose is a special rubber hose that connects the power steering gear or the power steering fluid cooler on some models, back to the fluid reservoir mounted on the power steering pump. The power steering gear has a steel fitting attached to its outlet port that the return hose is pushed onto. On vehicles equipped with a power steering fluid cooler, the return hose attaches to the cooler outlet tube instead of the steering gear steel fitting. The hose is secured to either component using a standard adjustable clamp. The other end of the power steering fluid return hose attaches to the power steering fluid reservoir on the power steering pump using a standard adjustable clamp. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL - POWER STEERING FLUID PRESSURE HOSE 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. 3. Back out the tube nut securing the power steering fluid pressure hose to the gear. 4. Open the routing clips on the right side of the power steering gear and remove the power steering fluid pressure hose tube from the routing clips. At the same time, remove the pressure hose tube from the gear. 5. Lower the vehicle. 6. Remove the bolt securing the hose routing clip in place on the right engine motor mount. Remove the power steering fluid pressure hose from 7. Back out the tube nut securing the power steering fluid pressure hose to the power steering pump and remove the hose from the pump. 8. Remove the power steering pressure hose from the engine compartment. INSTALLATION - POWER STEERING FLUID PRESSURE HOSE 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 back of 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 power steering fluid. 3. Attach the power steering fluid pressure hose to the outlet fitting on the bottom of the power steering pump. Tighten the pressure hose tube nut to a torque of 34 Nm (25 ft. lbs.). 4. Install the power steering fluid pressure hose in the routing clip and attach the clip to the right engine mount. Tighten the hose routing clip bolt 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 gear port. Replace the used O-ring with new. Lubricate the O-ring with power steering fluid. 7. Attach the power steering fluid pressure hose to the port on the power steering gear. Start the tube nut threads into the gear, but do not tighten it at this time. 8. Open the routing clips on the right side of the power steering gear and install the power steering fluid pressure hose into the routing clips. Close the clips. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 809 9. Tighten the pressure hose tube nut at the gear to a torque of 34 Nm (25 ft. lbs.). 10. Lower the vehicle. 11. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair 12. Check for leaks at all hose connections. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 810 Power Steering Line/Hose: Service and Repair Hose - Return REMOVAL- POWER STEERING FLUID RETURN HOSE 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. 3. Remove the hose clamp securing the return hose to the cooler. Slide the hose off the end of the cooler tube. 4. Lower the vehicle. 5. Remove the bolt securing the hose routing clip in place on the right engine mount. Remove the power steering fluid return hose from the routing clip. 6. Remove the hose clamp securing the return hose to the power steering fluid reservoir. Slide the hose off the end of the reservoir fitting. 7. Remove the power steering return hose from the engine compartment. INSTALLATION - POWER STEERING FLUID RETURN HOSE 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 on the power steering fluid reservoir, then route the rest of the hose along the right side of the engine. Guide the gear end of the hose down behind the back of 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 power steering fluid return hose in the hose routing clip and attach the clip to the right engine mount. Tighten the hose routing clip bolt 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 gear port fitting or power steering fluid cooler port. 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. See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair 11. Check for leaks at all hose connections. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 815 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 816 Brake Fluid: Description and Operation 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 an container which has been left open. An open container 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Hydraulic Fluid DOT 3 Brake Fluid Conforming to J1703 Standards Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ ............................................... 6.2Liters ( 6.5 qts ) Note: Includes heater and recovery/reservoir bottle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 824 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 825 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 826 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 -59°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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 831 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 832 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 833 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 834 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 835 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Estimated Service Fill .......................................................................................................................... ...................................................... 3.8Liters (4.0 Qt) Overhaul Fill with Empty Converter .......................................................................................................................................................... 8.1Liters (8.6 Qt) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 838 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ..................................... Mopar ATF + 4, Type 9602 NOTE: Dexron III / Mercon is not recommended. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 839 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 840 Fluid - A/T: Testing and Inspection FLUID LEVEL AND CONDITION CHECK NOTE: The transmission and differential sump have a common oil sump with a communicating opening between the two. FLUID LEVEL CHECK 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. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82°C or 180°F). The fluid level is correct if it is in the HOT region (crosshatched area) on the fluid level indicator (Fig. 159). 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, the air bubbles can cause overheating, fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and servo operation. Foaming can also result in fluid escaping from the transaxle dipstick where it may be mistaken for a leak. 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 overhaul is needed. 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. 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 needed. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check Procedure for Checking Fluid Level To properly check the automatic transaxle fluid level, 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 at 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 and determine if the fluid is hot or warm. Hot fluid is approximately 180°F (82°C) that is the normal operating temperature after the vehicle has been driven at least 15 miles. The fluid cannot be comfortable held between the finger tips. Warm is when fluid is between 85° to 125°F (29° to 52°C). 6. Wipe the dipstick clean and reinsert until seated. Remove dipstick and note reading. If the fluid is hot, reading should be in the cross hatched area marked "HOT" between the upper two holes in the dipstick. If the fluid is warm, the fluid level should be between the lower two holes, into the area marked "WARM". If the fluid level shows low, add sufficient transmission fluid to bring to the proper level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 843 Fluid - A/T: Service and Repair Fluid and Filter Change STANDARD PROCEDURE - FLUID AND FILTER CHANGE NOTE: For the recommended maintenance (fluid/filter change) intervals for this transaxle, (Refer to MAINTENANCE) NOTE: Only fluids of the type labeled Mopar(R) 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. NOTE: 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. Remove oil filter-to-valve body screws (Fig. 160). 4. Remove oil filter and gasket (Fig. 161). 5. Install a new filter and gasket (Fig. 161). 6. Clean the oil pan and magnet. Reinstall pan using new Mopar(R) Silicone Rubber Adhesive Sealant. Torque oil pan bolts to 19 Nm (165 inch lbs.). 7. Pour four quarts of Mopar(R) ATF +4 (Automatic Transmission Fluid-Type 9602) through the dipstick opening. 8. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 844 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick (Fig. 162). 10. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 11. 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 TM 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(R) 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 "ADD" mark on the dipstick (Fig. 162). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transaxle NV T350 (A-578) ........................................................................................................................................ 2.4 2.7Liters (2.5 - 2.8 Qt) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 849 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type ................................................................................................................. Mopar ATF +4 Automatic Transmission Fluid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 850 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 851 Fluid - M/T: Service and Repair FLUID DRAIN AND FILL All NV T350 (A-578) 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). All NV T350 (A-578) 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 following chart. Wipe the outside of the transaxle if any lubricant spills. MV T350 (A-578) MANUAL TRANSAXLE FLUID FILL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Additives/Supplements Engine Oil: Technical Service Bulletins Engine Oil - Additives/Supplements NUMBER: 09-003-01 GROUP: Engine DATE: May 4, 2001 SUBJECT: Engine Oil Additives/Supplements OVERVIEW: This bulletin reinforces a requirement to cease the current practice of using supplemental oil additive treatments in all DaimlerChrysler engines. MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 (KJ) Liberty 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RG) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (ST) Sebring Coupe 2001 (SR) Viper 2001 (TJ) Wrangler 2001 (WG) Grand Cherokee (International Markets) 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO ALL DAIMLERCHRYSLER MODELS/ENGINES BUILT BEFORE AND AFTER THE 2001 MODEL YEAR. DISCUSSION Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: ^ Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee our emissions performance to 80,000 miles and new requirements of 150,000 miles. ^ Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. ^ Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ .............................................................. 4.5 Qt (US) Engine Oil without Filter ....................................................................................................................... .............................................................. 4.0 Qt (US) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 858 Engine Oil: Fluid Type Specifications Engine Oil Type Below 100°F (38°C) ............................................................................................................................. .................................................... 5W-30 (Preferred) Above 0°F (-18°C) ............................................ ....................................................................................................................................................... 10W-30 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 859 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 860 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. 112) and observe oil level. Add oil only when the level is at or below the ADD mark (Fig. 113). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 861 Engine Oil: Service and Repair ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Service Intervals. 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. Hoist and support vehicle on safety stands. Refer to Vehicle Lifting. 3. Remove oil fill cap. Refer to (Fig. 112). 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Remove oil filter. 7. Install and tighten drain plug in crankcase. 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. Refer to the WARNING. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 866 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 867 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 868 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 869 Power Steering Fluid: Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 870 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 871 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. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the dipstick level should indicate FULL (optimum level is at the FULL line). Do not overfill the power steering system. In all power steering systems, use only Mopar Power Steering Fluid (MS-9933), or its equivalent. NOTE: Do not use any type of automatic transmission fluid in the power steering system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Refrigerant Before July 1 ..................................................................................................................................................... 765 g (27 oz or 1.69 lbs) R134a Refrigerant After July 1 ............................................................................................................ .......................................................... 851 g (1.88 lbs) See TSB # 24-23-99 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 876 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 877 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 878 http://www.macsw.org/ Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 883 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 884 Refrigerant Oil: Service and Repair 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. The 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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. 3. Fill the brake fluid reservoir with Mopar brake fluid, or an 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. NOTE: It is not necessary to bleed the entire hydraulic system after replacing just the master cylinder unless the brake system has been open to air for an excessive amount of time or air is present in the lines. Only the master cylinder must be bled and filled. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 889 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the Antilock Brake System (ABS) hydraulic system, refer to ABS 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 having a bleeder screw open during the bleeding process. 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 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 890 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 891 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 Antilock Brake System (ABS) though, particularly the Integrated Control Unit (ICU) (Hydraulic Control Unit [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 (DLC). 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 Controller Antilock Brake (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 895 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations 8w-11-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 900 Circuit Breaker: Diagrams Fuse Block (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 901 Circuit Breakers (LHD) Fuse Block (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 902 Circuit Breakers (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 907 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 908 Fuse: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 909 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 910 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 911 Fuse: Diagrams Fuse Block (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 912 Fuses (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 913 Fuse Block (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 914 Fuses (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 915 Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 916 Fuses (PDC) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block Fuse: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 919 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 920 Fuse: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 921 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block > Page 922 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block Fuse Block: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block > Page 927 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block > Page 928 Fuse Block: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block > Page 929 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block > Page 930 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 933 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 934 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 935 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 936 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 937 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 938 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 939 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Fuse Block: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 948 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 949 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 950 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Fuse Block: Electrical Diagrams 8w-11-2 Schematics Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 952 8w-15-4 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 953 8w-15-5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 954 8w-15-6 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 955 8w-15-7 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 956 8w-15-8 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 957 8w-15-9 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 959 8w-15-10 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 960 8w-15-11 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 961 8w-15-12 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 962 8w-15-13 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 963 8w-15-14 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 964 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block Fuse Block: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 967 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 968 Fuse Block: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 969 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block > Page 970 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 971 Fuse Block: Description and Operation 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 Hock 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 972 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 977 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 978 Relay Box: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 979 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block > Page 980 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 983 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 984 Relay Box: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 985 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block > Page 986 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Application and ID > Page 991 Malfunction Indicator Lamp: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 995 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > NHTSA01V039000 > Feb > 01 > Recall 01V039000: Label 'Recommended Tire Size' Tires: Recalls Recall 01V039000: Label 'Recommended Tire Size' Vehicle Description: Passenger vehicles built with 15" wheels, equipped with an R/T package. Certain vehicles were equipped with an incorrect tire placard. The vehicles were equipped with P195/50R16 tires but the tire placard indicated that the recommended tire sizes were P185/65R14 and P185/65R15. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." The label specifies the wrong recommended tire size. This could cause the owner to select incorrect replacement tires. Owners will be provided with a correct label and installation instructions. Owner notification is expected to begin during February 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory Technical Service Bulletin # 972 Date: 010201 Recall - Incorrect Tire Size Label Installed at Factory February 2001 Dealer Service Instructions for: Safety Recall No. 972 - Tire Label Models 2001 (PL) Dodge Neon R/T NOTE: This recall applies only to the above vehicles built through October 24, 2000 (MDH 1024XX). Safety Recall No. 961 also involves tire label replacement, but applies to 2001 model year Neon vehicles equipped with the Sport Appearance Package. To ensure prompt payment and accurate service completions, dealers must verify which recall the vehicle is involved in prior to submitting a claim. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 130 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label with out charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, P/N 04656997AA or P/N 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 1009 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles 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, then type "0RD972". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 1010 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label Technical Service Bulletin # 961 Date: 001201 Recall - Incorrect Tire Size Label December 2000 Safety Recall No. 961 - Tire Label Models 2001 (PL) Dodge Neon NOTE: This recall applies only to the above vehicles equipped with the Sport Appearance Package (Sales Code - ADV) built through October 24, 2000 (MDH 102419). IMPORTANT: Some of the vehicles within the above build period have already been repaired and, therefore, have been excluded from this recall IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 1,600 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label without charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, PN 04656997AA or PN 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 1015 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown: NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Functions 53 and VIP All involved vehicles 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, then type "0RD961". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 1016 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA01V039000 > Feb > 01 > Recall 01V039000: Label 'Recommended Tire Size' Tires: All Technical Service Bulletins Recall 01V039000: Label 'Recommended Tire Size' Vehicle Description: Passenger vehicles built with 15" wheels, equipped with an R/T package. Certain vehicles were equipped with an incorrect tire placard. The vehicles were equipped with P195/50R16 tires but the tire placard indicated that the recommended tire sizes were P185/65R14 and P185/65R15. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." The label specifies the wrong recommended tire size. This could cause the owner to select incorrect replacement tires. Owners will be provided with a correct label and installation instructions. Owner notification is expected to begin during February 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory Technical Service Bulletin # 972 Date: 010201 Recall - Incorrect Tire Size Label Installed at Factory February 2001 Dealer Service Instructions for: Safety Recall No. 972 - Tire Label Models 2001 (PL) Dodge Neon R/T NOTE: This recall applies only to the above vehicles built through October 24, 2000 (MDH 1024XX). Safety Recall No. 961 also involves tire label replacement, but applies to 2001 model year Neon vehicles equipped with the Sport Appearance Package. To ensure prompt payment and accurate service completions, dealers must verify which recall the vehicle is involved in prior to submitting a claim. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 130 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label with out charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, P/N 04656997AA or P/N 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 1026 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles 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, then type "0RD972". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 1027 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label Technical Service Bulletin # 961 Date: 001201 Recall - Incorrect Tire Size Label December 2000 Safety Recall No. 961 - Tire Label Models 2001 (PL) Dodge Neon NOTE: This recall applies only to the above vehicles equipped with the Sport Appearance Package (Sales Code - ADV) built through October 24, 2000 (MDH 102419). IMPORTANT: Some of the vehicles within the above build period have already been repaired and, therefore, have been excluded from this recall IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 1,600 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label without charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, PN 04656997AA or PN 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 1032 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown: NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Functions 53 and VIP All involved vehicles 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, then type "0RD961". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 1033 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1034 Tires: Description and Operation DESCRIPTION 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 proper tire rotation interval. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1035 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 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1036 - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Fig. 2 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 1039 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 1040 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 PROCEDURES 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 1041 Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure. Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION Daimler Chrysler Corporation advocates driving at safe speeds within posted speed limits. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1044 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1048 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1049 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 should 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1050 Wheels: Service and Repair CLEANING - ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Any of the "DO NOT USE" items listed below WILL damage chrome plated and painted aluminum wheels. DO NOT USE: any abrasive metal cleaner - any abrasive cleaning pad or brush - any cleaner that contains an acid (this will immediately react with and discolor the chromium surface) - chrome polish (unless it is buffed off immediately after application) - oven cleaner - a car wash that uses carbide-tipped wheel cleaning brushes Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Suspension Bearing Retainer Plate bolt 250 in.lb Driveshaft Hub Nut 180 ft.lb Wheel Mounting Nuts 100 ft.lb Rear Suspension Knuckle Retaining Nut 160 ft.lb Wheel Mounting Nuts 80 - 110 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 1055 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB/BEARING The wheel bearing and hub are pressed into the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 1058 Wheel Bearing: Description and Operation Rear HUB/BEARING DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 1059 The hub and bearing is mounted on the rear knuckle's spindle. The hub and bearing adapts the tire and wheel assembly to the knuckle. It's bearing allows the tire and wheel assembly to rotate freely on the vehicle. All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. The only serviceable components of the hub and bearing are the wheel mounting studs. If a vehicle is equipped with antilock brakes, the tone wheels for the rear wheel speed sensors are pressed onto the hub. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 1062 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING (REAR) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 1063 The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. With the wheel, disc brake rotor or brake drum removed, rotate the hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub and bearing will require replacement. The bearing is not serviceable alone. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLY (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. 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. 2. Using Remover, Special Tool 4150A, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1066 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1067 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1068 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 honoring when 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1069 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 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1070 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1071 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1072 Wheel Bearing: Service and Repair Rear REMOVAL 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 any retainer clips from the wheel mounting studs, then pull the brake drum off the hub and bearing. 4. 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. 5. Remove the dust cap from the hub and bearing assembly. 6. Remove the retaining nut, then the hub and bearing from the knuckle's spindle. INSTALLATION 1. 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.). 2. Install the dust cap on the end of the hub and bearing. 3. 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.). 4. 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.). 5. Lower the vehicle to ground level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 22-002-01 > Mar > 01 > Wheel Covers - Rattles on Bumps Wheel Cover: Customer Interest Wheel Covers - Rattles on Bumps NUMBER: 22-002-01 GROUP: Wheels/Tires DATE: Mar. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-002-00, DATED OCTOBER 6, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Wheel Cover Rattle - 14" Steel Wheels OVERVIEW: This bulletin involves the replacement of all four wheelcovers with revised parts. MODELS: 2000 - 2001 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO DECEMBER 12, 2000 (MDH 1212XX) EQUIPPED WITH 14" STEEL WHEELS (SALES CODE W4U). SYMPTOM/CONDITION: Rattle sound coming from the wheel cover over bumps. DIAGNOSIS: Drive the vehicle over a bump and listen for the rattle sound. If the rattle is heard, remove the wheel covers and verify the sound is gone. If the noise is gone with the wheel covers removed, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Install the four wheel covers onto the vehicle and torque nuts to 25 in.lbs. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 22-002-01 > Mar > 01 > Wheel Covers - Rattles on Bumps Wheel Cover: All Technical Service Bulletins Wheel Covers - Rattles on Bumps NUMBER: 22-002-01 GROUP: Wheels/Tires DATE: Mar. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-002-00, DATED OCTOBER 6, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Wheel Cover Rattle - 14" Steel Wheels OVERVIEW: This bulletin involves the replacement of all four wheelcovers with revised parts. MODELS: 2000 - 2001 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO DECEMBER 12, 2000 (MDH 1212XX) EQUIPPED WITH 14" STEEL WHEELS (SALES CODE W4U). SYMPTOM/CONDITION: Rattle sound coming from the wheel cover over bumps. DIAGNOSIS: Drive the vehicle over a bump and listen for the rattle sound. If the rattle is heard, remove the wheel covers and verify the sound is gone. If the noise is gone with the wheel covers removed, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Install the four wheel covers onto the vehicle and torque nuts to 25 in.lbs. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Page 1086 Wheel Cover: Description and Operation WHEEL COVER DESCRIPTION This vehicle uses a bolt-on type wheel cover on models with steel wheels. The wheel cover is attached to the wheel using the 5 plastic nuts located in the wheel cover. The nuts in the wheel cover thread onto a special externally threaded wheel nut to retain the wheel cover to the wheel. Each wheel cover retaining nut is retained in the wheel cover and will stay on the wheel cover once it is unthreaded from the wheel nut. If required, the retaining nut can be removed from the wheel cover and replaced as a separate part of the wheel cover. The bolt-on wheel cover cannot be removed from the wheel until all 5 wheel cover retaining nuts are unthreaded from the wheel mounting nuts. At that time the wheel cover can easily be removed from the wheel by hand. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover Wheel Cover: Service and Repair Wheel Cover REMOVAL - WHEEL COVER NOTE: When unthreading the wheel cover retaining nuts from the wheel nuts, it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the wheel cover retaining nuts. 1. Unthread the 5 nuts attaching the wheel cover to the wheel nuts. 2. Grasp the wheel cover and pull straight outward from the wheel. This will remove the wheel cover from the wheel. INSTALLATION - WHEEL COVER 1. Align the valve notch in the wheel cover with the valve stem on the wheel. Align the wheel cover retaining nuts with the externally threaded wheel nuts. 2. By hand, start to thread all 5 of the wheel cover retaining nuts onto the externally-threaded wheel nuts. NOTE: When tightening the wheel cover retaining nuts it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the wheel cover retaining nuts. NOTE: To avoid rattling of the wheel cover, be sure all five retaining nuts are correctly tightened using the procedure described in the following step. 3. Progressively tighten each of the wheel cover retaining nuts following the pattern shown in the figure. Repeat the tightening sequence at least one more time. If a retaining nut "jumps a thread (slips), which is an override feature of the retaining nut, retighten all the nuts again following the proper tightening sequence to a point just prior to the thread slip occurring. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover > Page 1089 Wheel Cover: Service and Repair Wheel Cover Retaining Nut REMOVAL - WHEEL COVER RETAINING NUT 1. Remove the wheel cover from the wheel. NOTE: The retaining nut flange cannot be forced past the large retaining tab. When removing the retaining nut from wheel cover, the flange on the nut must instead be forced past the 2 small retaining tabs. 2. From the back side of the wheel cover, push outward and tilt the retaining nut sideways forcing the flange on the retaining nut past the 2 small retaining tabs in the retaining nut hole of the wheel cover, then remove the retaining nut from the wheel cover by pushing or pulling it from the hole in the wheel cover. INSTALLATION - WHEEL COVER RETAINING NUT 1. Install the retaining nut into the hole of wheel cover with the retaining nut flange positioned under the large retaining tab first, then push the nut flange past the small tabs snapping the nut into place. 2. Reinstall the wheel cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Driveshaft-to-Hub/Bearing 180 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 1098 Wheel Fastener: Specifications Wheel Mounting Lug Nut Hex Size 19mm Wheel Mounting Stud Size M12 x 1.5mm Wheel Mounting Lug nut 100 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1101 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1102 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 deepwell 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1103 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1109 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. Disconnect the ignition coil electrical connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Bearing Clearance- Diametrical 0.0021 - 0.0037 inch Bearing Clearance (Max. Allowable) 0.0047 inch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Journal Diameter Number 1 1.619 - 1.6199 in Number 2 1.634 - 1.635 in Number 3 1.650 - 1.651 in Number 4 1.666 - 1.668 in Number 5 1.682 - 1.6829 in Bearing Clearance Diametrical 0.0027 - 0.003 in Max. Allowable 0.0047 in End Play 0.002 - 0.015 in Standard Engine - Lift (Zero Lash) Intake 0.283 in Exhaust 0.277 in High Output R/T Engine Lift (Zero Lash) Intake 0.345 in Exhaust 0.315 in Exhaust Valve Timing -Standard Engine Closes 5.4 deg ATDC Opens 43.7 deg BBDC Duration 229.1 deg Exhaust Valve Timing - High Output Engine Closes 3.3 deg ATDC Opens 45.2 deg BBDC Duration 228.6 deg Intake Valve Timing Standard Engine closes 41.1 deg ABDC Opens 13.9 deg ATDC Duration 207.2 deg Valve Overlap 84.8 deg Intake Valve Timing High Output Closes 45.4 deg ABDC Opens 13.4 deg ATDC Duration 212 deg Valve Overlap 90.7 deg Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1120 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 duration. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures STANDARD PROCEDURE - 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. 22). b. Using a suitable tool, move camshaft to rearward 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1123 Camshaft: Removal and Replacement REMOVAL 1. Disconnect battery negative cable. 2. Remove the battery. 3. Disconnect the IAT sensor electrical connector. 4. Disconnect the following; air intake duct at intake manifold, throttle cables, TPS and IAC from throttle body, air make-up hose at air cleaner housing. 5. Remove the air cleaner housing assembly. 6. Remove the battery tray. 7. Remove the timing belt and camshaft sprocket. 8. Remove the cylinder head cover. 9. Mark rocker arm shaft assemblies so that they are installed in their original positions. 10. Remove rocker arm and shafts assembly. 11. Drain cooling system below heater hose level. 12. Disconnect the ECT sensor electrical connector. 13. Disconnect hoses from heater supply and return tubes. 14. Remove heater tube support bracket bolts at rear of cylinder head. 15. Remove PDC attaching screws and reposition for camshaft removal clearance. 16. Remove camshaft sensor and camshaft target magnet. 17. Carefully remove camshaft from the rear of cylinder head. Reposition heater tubes and PDC for camshaft clearance. 18. Remove the camshaft seal. CLEANING Clean camshaft with a suitable solvent. INSPECTION 1. Inspect camshaft bearing journals for damage and binding (Fig. 23). 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. 23) 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. 2. Carefully install the camshaft into the cylinder head. Reposition the PDC and heater tubes for clearance. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1124 6. Install the front camshaft seal. 7. Install the timing belt rear cover. CAUTION: Do Not use a impact wrench for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. Use a hand wrench only. 8. Install camshaft sprocket and tighten to 115 Nm (85 ft. lbs.). 9. Install timing belt tensioner and timing belt. 10. Install rocker arm assemblies in correct order as removed. Tighten the rocker arm assemblies in sequence shown in (Fig. 24) to 28 Nm (250 in. lbs.). 11. Install the cylinder head cover. 12. Install ignition coil and spark plug cables. Tighten ignition coil fasteners to 12 Nm (105 in. lbs.). 13. Install the heater tube bracket attaching bolt. 14. Connect the heater hoses to the heater tubes. 15. Connect the ECT electrical connector. 16. Install the PDC attaching screws. 17. Install the battery tray. 18. Install the air cleaner housing assembly. 19. Connect all linkages and connectors to throttle body. 20. Connect the IAT sensor. 21. Install the battery and connect cables. 22. Perform camshaft and crankshaft timing relearn procedure as follows: - 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. - Turn the ignition switch on and access the "miscellaneous" screen. - Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Inside Diameter 0.787 - 0.788 in Rocker Arm Shaft Clearance 0.0006 -0.0021 in Rocker Arm Ratio 1.4 : 1 Rocker Arm Shaft Bolts 250 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1128 Rocker Arm Assembly: Testing and Inspection LASH ADJUSTER (TAPPET) 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. - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1129 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. 35). 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. 36). 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. 1. Lubricate the rocker arms and spacers. Install onto shafts in their original position (Fig. 35). 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1130 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. 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. 37). Install the retainers in their original positions on the exhaust and intake shafts (Fig. 35). 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. 38). 5. Install the cylinder head cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1135 Connecting Rod Bearing: Service and Repair CONNECTING ROD AND BEARING - FITTING 1. Measure connecting rod bearing clearance using Plastigage (Fig. 53). For more information on use of Plastigage; Refer to Engine; Service and Repair; Standard Procedures. Refer to Specifications for connecting rod specifications. 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. 54). Refer to Specifications for connecting rod specifications. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 1140 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts ..................................................................................................................................................... 27 Nm (20 ft. lbs.) + 1/4 turn Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1141 Connecting Rod: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1142 Connecting Rod: Service and Repair 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. 81). 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. 82) for identification. 5. Pistons will have a stamping in the approximate location shown in (Fig. 81). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1143 8. To protect crankshaft journal and fractured rod surfaces, install Special Tool 8189, connecting rod guides onto connecting rod (Fig. 83). 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. 90). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1144 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 84). 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. 81). 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. 83). 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. 12. Install the cylinder head. 13. Install the oil pan. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 1149 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1150 Crankshaft Main Bearing: Service and Repair CRANKSHAFT MAIN BEARINGS 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. 65). 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. 65). 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. 66). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1151 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. 67). 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: - 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. 68) 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. 68). 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. 68). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1155 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. 55). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 56). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1158 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 the timing belt. 8. Remove the timing belt tensioner. 9. Remove camshaft sprocket and rear timing belt cover. 10. Remove crankshaft sprocket. 11. Remove lower torque strut/air conditioning compressor mounting bracket from engine (Fig. 57). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1159 12. Remove oil filter and adapter (Fig. 58). 13. Remove oil pan. 14. Remove oil pump pick-up tube. 15. Remove oil pump. 16. Remove crankshaft position sensor (Fig. 58). 17. 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. 18. 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. 19. Remove all main bearing cap and bedplate bolts from the engine block (Fig. 59). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1160 20. 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. 21. Bedplate should be removed evenly from the cylinder block dowel pins. 22. 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. 60). NOTE: The upper and lower main Bearing shells are Not interchangeable. The lower shells have a revised tab to prevent improper installation. INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 61). 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. 60). 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 min (0.0006 inch), 0.032 mm (0.0012 inch), 0.250 mm (0.010 inch). Never install an Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1161 undersize bearing that will reduce clearance below specifications. INSTALLATION 1. Install the main bearing shells with the lubrication groove in the cylinder block. Install O-ring into recess in the block (Fig. 62). 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. 63). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1162 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. 64). 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. 64). 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. 64). 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. 16. Install lower torque strut/air conditioning compressor mounting bracket to engine (Fig. 57). 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 the 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 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 and access the "miscellaneous" screen. - Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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. 3). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1166 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 110 volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1167 Engine Block Heater: Service and Repair REMOVAL 1. Drain the cooling system. 2. Detach power cord plug from heater (Fig. 4). 3. Loosen screw in center of heater. Remove heater assembly (Fig. 4). INSTALLATION 1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop positioned upward (Fig. 4). 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Connect power cord to block heater (Fig. 4). 5. Fill the cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1171 Harmonic Balancer - Crankshaft Pulley: Service and Repair 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. 92). INSTALLATION 1. Install crankshaft vibration damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792 (Fig. 93). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1172 2. Install vibration damper bolt. Using Special Tool 6847 and a torque wrench, tighten bolt to 136 Nm (100 ft. lbs.) (Fig. 94). 3. Install accessory drive belts. 4. Install the right inner splash shield and lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1176 Piston: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 80). Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown in (Fig. 79). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1179 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. 81). 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. 82) for identification. 5. Pistons will have a stamping in the approximate location shown in (Fig. 81). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1180 8. To protect crankshaft journal and fractured rod surfaces, install Special Tool 8189, connecting rod guides onto connecting rod (Fig. 83). 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. 90). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1181 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 84). 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. 81). 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. 83). 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. 12. Install the cylinder head. 13. Install the oil pan. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 in Clearance in Connecting Rod Interference Diameter 0.8268 - 0.8269 in Length 2.943 - 2.963 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 85). 2. Check piston ring to groove side clearance (Fig. 86). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1190 Piston Ring: Service and Repair Piston Ring - Removal and Installation REMOVAL NOTE: The identification mark on face of upper and intermediate piston rings must point toward piston crown. 1. Using a suitable ring expander, remove upper and intermediate piston rings (Fig. 87). 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 Install rings with manufacturers identification mark facing up, to the top of the piston (Fig. 88). 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. 1. Install oil ring expander (Fig. 88). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1191 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. 89). 3. Install No. 2 piston ring and then No. 1 piston ring (Fig. 88). 4. Position piston ring end gaps as shown in (Fig. 90). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1199 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Inside Diameter 0.787 - 0.788 in Rocker Arm Shaft Clearance 0.0006 -0.0021 in Rocker Arm Ratio 1.4 : 1 Rocker Arm Shaft Bolts 250 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1203 Rocker Arm Assembly: Testing and Inspection LASH ADJUSTER (TAPPET) 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. - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1204 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. 35). 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. 36). 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. 1. Lubricate the rocker arms and spacers. Install onto shafts in their original position (Fig. 35). 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1205 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. 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. 37). Install the retainers in their original positions on the exhaust and intake shafts (Fig. 35). 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. 38). 5. Install the cylinder head cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 105 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1209 Valve Cover: Service and Repair REMOVAL 1. Disconnect make-up air (Fig. 25) and PCV (Fig. 26) hoses from cylinder head cover. 2. Remove ignition coil and spark plug cables (Fig. 27). 3. Remove cylinder head cover bolts. 4. Remove cylinder head cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1210 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. 28). 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. 27). Tighten ignition coil fasteners to 12 Nm (105 in. lbs.). 4. Connect make-up air (Fig. 25) and PCV (Fig. 26) hoses. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 in Guide Bore Diameter (std) 0.4330 - 0.4338 in Guide Height (spring seat to guide tip) 0.521 - 0.541 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle 45 deg Seat Diameter Intake 1.299 in Exhaust 1.102 in Runout (max.) 0.002 in Valve Seat Width Intake and Exhaust 0.035 - 0.051 in Service Limit - Intake 0.079 in Service Limit - Exhaust 0.098 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Standard Engine Free Length 1.84 in Nominal Force (Valve Closed) 70 lbf at 1.57 in Nominal Force (Valve Open) 160 lbf at 1.28 in Installed Height 1.580 in Valve Spring High Output R/T Free Length 2.13 in Nominal Force (Valve Closed) 72 lbf at 1.57 in Nominal Force (Valve Open) 167 lbf at 1.28 in Installed Height 1.580 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1220 Valve Spring: Description and Operation OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1221 Valve Spring: Service and Repair REMOVAL CYLINDER HEAD OFF 1. With cylinder head removed, compress valve springs using the valve spring compressors shown in (Fig. 44). 2. Remove valve retaining locks, valve spring retainers and valve springs. 3. Remove valve stem seal assembly. 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. 45) compress valve springs and remove valve locks. 6. Remove the valve spring. 7. Remove the valve stem seal. INSPECTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1222 When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 46). 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. Refer to Engine Specifications to obtain specified height and allowable tensions. 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1223 positioned toward the cylinder head (spring seat) (Fig. 49). 3. Position valve spring and retainer on spring seat (Fig. 48) or (Fig. 49). 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. 47). 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. CYLINDER HEAD ON 1. Install valve stem seal assembly. 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. 49). 2. Position valve spring and retainer on spring seat (Fig. 48) or (Fig. 49). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Face Angle Intake and Exhaust 45 - 45.5 deg Head Diamter Intake 1.303 - 1.313 in Exhaust 1.124 - 1.135 in Valve Margin - Intake 0.0452 - 0.0583 in Service Limit 1/32 in Valve Margin - Exhaust 0.058 - 0.071 in Service Limit 3/64 in Valve Length Overall Intake 4.503 - 4.523 in Exhaust 4.603 - 4.623 in Valve Stem tip Height Intake 1.76 - 1.80 in Exhaust 1.71 - 1.75 in Valve Stem Diameter Intake 0.2337 - 0.2344 in Exhaust 0.2326 - 0.23333 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1227 Valve: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1228 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. 32) approximately 60 min (2.36 inch) below the valve lock grooves. NOTE: Valve stems are chrome plated and should not be polished (Fig. 32). 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. 3. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 33). 4. Move valve to and from the indicator. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1229 5. Check valve guide height (Fig. 34). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1232 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. 29). Intake valves with less than 0.95 mm (1/32 inch) margin and exhaust valves with less than 1.05 mm (3/64 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. 30). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1233 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. 31). The valve tip chamfer is needed to be reground to prevent seal damage when the valve is installed. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION The accessory drive consist of two Poly-V type drive belts (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1238 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT DIAGNOSIS Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1239 Drive Belt: Service and Repair REMOVAL Power Steering Pump And Air Conditioning Compressor Belt 1. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 3) until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner. 2. Remove the drive belt (Fig. 4). Generator Belt 1. Remove power steering pump/air conditioning compressor drive belt. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1240 2. Loosen pivot bolt, then locking nut and adjusting bolt (Fig. 5). 3. Remove generator belt. NOTE: When installing drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. 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). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1241 NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION Power Steering Pump And Air Conditioning Compressor Belt 1. Install the drive belt (Fig. 4) over all the pulleys except for the power steering pump pulley. 2. Using a 17 mm wrench, rotate belt tensioner clockwise (Fig. 3) until belt can be installed on the power steering pulley. Release spring tension onto belt. 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. 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. Generator Belt 1. Install belt and/or adjust belt tension by tightening adjusting bolt. Adjust belt to specification shown in DRIVE BELT TENSION CHART. 2. Check belt tension using Special Tool 8371 Belt Tension Gauge Adapter, and the DRBIII using the following procedures: WARNING: DO NOT CHECK BELT TENSION WITH ENGINE RUNNING. a. Connect 8371 to the DRBIII following the instructions provided with tool. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1242 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 DRBIII screen. e. Adjust belt to obtain proper frequency (tension). Refer to DRIVE BELT TENSION CHART for specifications. 3. Tighten pivot bolt to 54 Nm (40 ft. lbs.) and locking nut to 54 Nm (40 ft. lbs.) (Fig. 5). 4. Install power steering pump and A/C compressor drive belt. DRIVE BELT TENSION CHART Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation Drive Belt Tensioner: Description and Operation DESCRIPTION The automatic belt tensioner (Fig. 1) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Page 1246 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 lb. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL UPPER TORQUE STRUT 1. Remove bolts attaching strut to shock tower bracket and engine mount bracket (Fig. 104). 2. Remove the upper torque strut. LOWER TORQUE STRUT 1. Raise vehicle on hoist. 2. Remove right side splash shield. 3. Remove bolts attaching lower strut to crossmember and strut bracket (Fig. 104). 4. Remove lower torque strut. INSTALLATION UPPER TORQUE STRUT 1. Position the upper torque strut into mounting locations (Fig. 104). 2. Install the mounting bolts and perform the torque strut adjustment procedure. LOWER TORQUE STRUT 1. Position lower torque strut into mounting locations (Fig. 104). 2. Install mounting bolts and perform torque strut adjustment procedure. 3. Install splash shield and lower vehicle Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1252 Engine Torque Strut: Service and Repair Adjustments 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. 105). NOTE: The floor jack must be positioned as shown in (Fig. 105) to prevent minimal upward lifting of the engine. 3. 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. 106). 4. With the engine held at the proper position, tighten both the upper and lower torque strut bolts to 118 Nm (87 ft. lbs.) (Fig. 104). 5. Remove the floor jack. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Additives/Supplements Engine Oil: Technical Service Bulletins Engine Oil - Additives/Supplements NUMBER: 09-003-01 GROUP: Engine DATE: May 4, 2001 SUBJECT: Engine Oil Additives/Supplements OVERVIEW: This bulletin reinforces a requirement to cease the current practice of using supplemental oil additive treatments in all DaimlerChrysler engines. MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 (KJ) Liberty 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RG) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (ST) Sebring Coupe 2001 (SR) Viper 2001 (TJ) Wrangler 2001 (WG) Grand Cherokee (International Markets) 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO ALL DAIMLERCHRYSLER MODELS/ENGINES BUILT BEFORE AND AFTER THE 2001 MODEL YEAR. DISCUSSION Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: ^ Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee our emissions performance to 80,000 miles and new requirements of 150,000 miles. ^ Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. ^ Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ .............................................................. 4.5 Qt (US) Engine Oil without Filter ....................................................................................................................... .............................................................. 4.0 Qt (US) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1266 Engine Oil: Fluid Type Specifications Engine Oil Type Below 100°F (38°C) ............................................................................................................................. .................................................... 5W-30 (Preferred) Above 0°F (-18°C) ............................................ ....................................................................................................................................................... 10W-30 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1267 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1268 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. 112) and observe oil level. Add oil only when the level is at or below the ADD mark (Fig. 113). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1269 Engine Oil: Service and Repair ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Service Intervals. 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. Hoist and support vehicle on safety stands. Refer to Vehicle Lifting. 3. Remove oil fill cap. Refer to (Fig. 112). 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Remove oil filter. 7. Install and tighten drain plug in crankcase. 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. Refer to the WARNING. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 15 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1273 Oil Filter: Service and Repair REMOVAL CAUTION: When servicing the oil filter (Fig. 114), 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. 114). 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. 114). Tighten to 21 Nm (15 ft. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter 60 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 1277 Oil Filter Adapter: Service and Repair REMOVAL 1. Remove the oil filter. 2. Remove assembly by unscrewing adaptor fitting (Fig. 133). 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. 133). 3. Install oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 105 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1281 Oil Pan: Service and Repair 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. 115). 5. Remove structural collar. 6. Remove lateral bending brace attaching bolts (Fig. 116). 7. Remove lateral bending brace (Fig. 116). 8. Remove transaxle dust cover (Fig. 116). 9. Remove oil pan bolts. 10. Remove oil pan. INSTALLATION 1. Clean oil pan and all sealing surfaces. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1282 2. Apply Mopar Silicone Rubber Adhesive Sealant at the oil pump to engine block parting line (Fig. 117). 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. 116). 6. Install lateral bending brace (Fig. 116). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 118). 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 PSI and 4 PSI. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure, within a maximum of 3 PSI of the switch's "Closed" circuit pressure point. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Description and Operation > Page 1286 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. 119). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 119). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID > Page 1293 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The low oil pressure warning lamp Will illuminate when the ignition switch is turned to the ON position without engine running. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. Fig.4 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. 4). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications High Output 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.). Standard Tighten fasteners using sequence shown to 12 Nm (105 in. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 1305 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts .............................................................................................................................................................. 23 Nm (200 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Description and Operation > Intake Manifold - High Output 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Description and Operation > Intake Manifold - High Output > Page 1308 Intake Manifold: Description and Operation Intake Manifold Standard DESCRIPTION The intake manifold is a molded plastic composition, attached to the cylinder head with fasteners. The manifold is a long branch design to enhance low and mid-range torque. OPERATION The intake manifold delivers air to the combustion chambers. This air allows the fuel delivered by the fuel injectors to ignite when the spark plug fire. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Description and Operation > Page 1309 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard Intake Manifold: Service and Repair Intake Manifold - Standard REMOVAL WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove the inlet air duct from intake manifold to throttle body. 3. Perform fuel system pressure release procedure before attempting any repairs. WARNING: WRAP SHOP TOWELS AROUND FUEL HOSE TO CATCH ANY GASOLINE SPILLAGE 4. Disconnect fuel supply line quick connect at the fuel tube assembly. 5. Disengage and remove fuel injector cover from retaining pins by pulling outward on cover (Fig. 134). 6. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with suitable covering. CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1312 7. Disconnect brake booster hose (Fig. 135) and PCV hose (Fig. 136) from intake manifold. 8. Disconnect Manifold Absolute Pressure (MAP) sensor electrical connector (Fig. 137). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1313 9. Disconnect knock sensor electrical connector (Fig. 138). 10. Disconnect wiring at starter. 11. Remove the intake manifold to lower support bracket bolts (Fig. 139). 12. Remove intake manifold screws and washers. Discard the fasteners. Remove intake manifold. INSPECTION Inspect manifold for cracks or distortions. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1314 Check for torn or missing O-rings at the mating surface of the manifold (Fig. 141). INSTALLATION Before installing manifold. Clean all mating surfaces. Replace all O-ring gaskets with new gaskets (Fig. 142). All intake manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used. 1. Install intake manifold onto cylinder head and tighten fasteners to 12 Nm (105 in. lbs.) in sequence shown in (Fig. 140). 2. Install intake manifold to lower support bracket bolts (Fig. 139). Tighten bolts to 11 Nm (95 in. lbs.). 3. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold, Tighten screws to 23 Nm (200 in. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1315 4. Connect PCV and brake booster hoses. 5. Inspect quick connect fittings for damage, replace if necessary. Apply a light amount of clean engine oil to fuel inlet tube. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position. 6. Install the fuel injector cover (Fig. 134). 7. Connect Manifold Absolute Pressure (MAP) Sensor wiring connector (Fig. 137). 8. Connect knock sensor connector, and wiring at starter. 9. Install inlet air duct to intake manifold and throttle body. Tighten clamp to 3 Nm (30 in. lbs.). 10. Connect negative cable to battery. 11. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1316 Intake Manifold: Service and Repair Intake Manifold - High Output 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. Remove fuel rail cover by pulling up to disengage from retaining pins (Fig. 143). 5. Disconnect fuel injector connector and harness from injectors and fuel rail. 6. Disconnect PCV hose from manifold (Fig. 145). 7. Remove the inlet air duct from intake manifold to throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1317 8. Remove bolt attaching lower intake manifold to support bracket (Fig. 144). 9. Remove engine oil dipstick from housing. 10. Disconnect electrical connectors from MAP sensor and MTV actuator (Fig. 145). 11. Remove bolts attaching intake manifold to cylinder head. 12. Move manifold forward for access to wiring connections (Fig. 147). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1318 13. Disconnect the knock sensor (Fig. 146). 14. Disconnect brake booster hose (Fig. 147). 15. 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. 148) 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. 6. Connect the knock sensor (Fig. 146). 7. Connect brake booster hose (Fig. 147). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Standard > Page 1319 8. Position manifold to cylinder head and install fasteners. Tighten fasteners in sequence shown in (Fig. 149) to 12 Nm (105 in. lbs.). 9. Install bolt securing lower manifold to bracket (Fig. 144). Tighten bolt to 28 Nm (250 in. lbs.). 10. Connect MAP sensor and MTV actuator electrical connection (Fig. 145). 11. Install engine oil dipstick 12. Connect inlet air duct to manifold and throttle body. 13. Connect PCV hose to manifold (Fig. 145). 14. Connect fuel injector connectors and harness to fuel rail. 15. Install fuel rail cover (Fig. 143). 16. Connect fuel supply line to fuel rail. 17. Connect negative cable to battery. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID > Page 1324 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The low oil pressure warning lamp Will illuminate when the ignition switch is turned to the ON position without engine running. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. Fig.4 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. 4). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL CAUTION: Do Not Rotate the camshaft or crankshaft when timing belt is removed damage to the engine may occur. 1. Remove the timing belt tensioner assembly. 2. Hold camshaft sprocket with Special Tools C-4687 and modified C-4687-1 as shown in (Fig. 20), while removing attaching bolt. 3. Remove sprocket from camshaft. 4. Remove the rear timing belt cover. 5. 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. 6. 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. 21). 2. Install the rear timing belt cover. 3. Install camshaft sprocket retaining bolt. Hold camshaft sprocket with Special Tools C-4687 and modified C-4687-1 (Fig. 20) and tighten bolt to 115 Nm (85 ft. lbs.). 4. Install timing belt tensioner, timing belt, front cover, and crankshaft vibration damper. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 74) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1332 1. Place Special Tool 6926-1 on crankshaft. This is a pilot tool with a magnetic base (Fig. 75). 2. Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal (Fig. 75). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1333 3. Drive the seal into the block using Special Tool 6926-2 and handle C-4171 (Fig. 76) until the tool bottoms out against the block (Fig. 77). 4. Install the flex plate. 5. Install the transaxle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Testing and Inspection Cylinder Head Gasket: Testing and Inspection CYLINDER HEAD GASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. Possible indications of the cylinder head gasket leaking between adjacent cylinders are: Loss of engine power - Engine misfiring - Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: Engine overheating - Loss of coolant - Excessive steam (white smoke) emitting from exhaust - Coolant foaming CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure. CYLINDER-TO-WATER JACKET LEAKAGE TEST WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED. VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident. CHEMICAL TEST METHOD Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 69). 5. Remove the crankshaft sprocket key from crankshaft (Fig. 70). CAUTION: Do not nick shaft seal surface or seal bore. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1340 6. Using Special Tool 6771, remove front crankshaft oil seal (Fig. 71). 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. 72), install seal until flush with cover. 2. Install the crankshaft sprocket key (Fig. 70). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1341 3. Install the crankshaft sprocket (Fig. 73) 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. 4. Install the timing belt. 5. Install crankshaft vibration damper. 6. Install accessory drive belts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL 1. Remove valve spring. 2. Remove valve stem seals by using a valve stem seal tool (Fig. 42). 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. 43). 2. Install valve spring. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 118). 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 PSI and 4 PSI. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure, within a maximum of 3 PSI of the switch's "Closed" circuit pressure point. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Page 1349 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. 119). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 119). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 1360 Timing Belt: Service and Repair REMOVAL 1. Remove the accessory drive belts. 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove the crankshaft damper. 4. Remove the lower torque strut. 5. Lower vehicle and place a jack under engine. 6. Remove the upper torque strut. 7. Remove the engine right mount to engine mount bracket through bolt. 8. Remove the power steering pump assembly and set aside. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 1361 9. Remove the engine mount bracket (Fig. 164). 10. Remove the timing belt front cover (Fig. 165). CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft. 11. Rotate crankshaft until timing marks are aligned at both the camshaft and crankshaft. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 1362 12. Loosen the timing belt tensioner fasteners (Fig. 166). CAUTION: DO NOT loosen, tighten, or remove the tensioner pivot bolt (Fig. 167). 13. 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. 14. For timing belt tensioner pulley assembly removal; refer to Timing Belt Tensioner; Service and Repair. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 1363 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. 168). 2. Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover (Fig. 169). 3. Move crankshaft to 1/2 mark before TDC (Fig. 170) for belt installation. 4. Install the timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket. 5. Move crankshaft sprocket to TDC to take up belt slack. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 1364 6. Re-set the hydraulic tensioner by placing tensioner body in a vise equipped with soft jaws (Fig. 171). 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. 171). 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. 172). 11. Pull the tensioner plunger retaining pin. Pretension is correct when the pin can be removed and installed into tensioner housing and plunger. 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks (Fig. 170) and (Fig. 169). 13. Check belt tension by installing pin into tensioner housing. If pin cannot be re-installed, repeat belt tension procedure. 14. Install the timing belt front cover. 15. Install the engine mount bracket. 16. Install the engine right mount to engine mount bracket through bolt. 17. Remove jack from under engine. 18. Install the upper torque strut. 19. Install power steering pump assembly. 20. Raise vehicle and install lower torque strut. 21. Install the crankshaft damper. 22. Install accessory drive belts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 1365 23. Install right inner splash shield. 24. Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows: - 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. - Turn the ignition switch on and access the "miscellaneous" screen. - Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications > Page 1369 Timing Belt Tensioner: Service and Repair REMOVAL 1. Remove the timing belt. 2. Remove the bolts attaching the tensioner pulley assembly to engine. 3. Remove the tensioner pulley assembly (Fig. 173). INSTALLATION 1. Position tensioner pulley assembly to the engine and install attaching bolts. Tighten bolts to 31 Nm (23 ft. lbs.) 2. Install the timing belt. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1373 Timing Cover: Service and Repair REMOVAL Front Cover 1. Remove accessory drive belts. 2. Remove crankshaft damper. 3. Remove lower and upper torque struts. 4. Position a jack under engine. Raise jack enough to support engine weight. 5. Remove right engine mount to engine mount bracket bolt. 6. Remove power steering pump assembly and set aside. 7. Remove right engine mount bracket. 8. Remove the timing belt front cover (Fig. 160). Rear Cover 1. Remove timing belt front cover. 2. Remove timing belt and timing belt tensioner. 3. Hold camshaft sprocket with Special Tools C-4687 and modified Adaptor C-4687-1 (Fig. 161), while removing attaching bolt. 4. Remove camshaft sprocket. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1374 5. Remove rear cover attaching bolts (Fig. 162). 6. Remove rear cover (Fig. 162). INSTALLATION Rear Cover 1. Install rear cover and tighten bolts to 12 Nm (105 in. lbs.) (Fig. 162). 2. Install camshaft sprocket. While holding sprockets with Special Tools C-4687 and modified Adaptor C-4687-1, tighten attaching bolt to 101 Nm (75 ft. lbs.). 3. Install timing belt tensioner assembly and timing belt. 4. Install front cover. Front Cover 1. Install front cover and tighten bolts to 12 Nm (105 in. lbs.). 2. Install engine front mount bracket. 3. Install right side engine mount to engine mount bracket bolt. 4. Remove jack from under engine. 5. Install power steering pump assembly. 6. Install upper and lower engine torque struts. 7. Install crankshaft damper. 8. Install accessory drive belts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1380 Fuel Pressure: Specifications Fuel System Volume Fuel System Volume Volume 1/4 Liter (1/2 pint) in 7 seconds Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1381 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1382 Tests 3 - 5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1383 Tests 6 - 10 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 pump capacity (volume) out of specs - Fuel pump relay fused B+ circuit - Fuel pump relay output circuit open Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1384 - Fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 600-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test, using a scan tool. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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. 9). 2. Install lid and tighten screws. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1396 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1401 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1402 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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..................................................................................................................................................... ............................................. 3500 ohms - 4900 ohms #2 #3..................................................................................................................................................... ............................................. 2950 ohms - 4100 ohms Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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(R) parts cleaner or equivalent. 2. Apply Mopar(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1417 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1421 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. Disconnect the ignition coil electrical connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1428 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1429 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1430 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(R) 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 inch lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1431 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 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 and access the "miscellaneous" screen. ^ Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ ............................................... 6.2Liters ( 6.5 qts ) Note: Includes heater and recovery/reservoir bottle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1437 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1438 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1439 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 -59°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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation > Page 1443 Coolant Line/Hose: Service and Repair 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(R) Dielectric Grease and install inlet tube into the cylinder block opening. 3. Install inlet tube fasteners and tighten to 12 Nm (105 inch lbs.). 4. Install intake manifold lower support bracket fasteners and tighten to 12 Nm (105 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair REMOVAL 1. Disconnect recovery hose from water outlet connector/thermostat housing. 2. Remove container attaching fasteners. 3. Remove coolant recovery container. INSTALLATION 1. Install coolant recovery container and tighten fasteners to 4 Nm (35 inch lbs.). 2. Connect recovery hose to water outlet connector/thermostat housing. 3. Fill container to proper level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 Radiator Cooling Fan Motor: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Radiator Fan Motor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1471 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. OPERATION 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). For wiring diagrams of the fan circuit, Refer to Appropriate Wiring Information. If the radiator fan is inoperative or a Diagnostic Trouble Code (DTC) related to fan control has been set, Refer to Appropriate Diagnostic Information for complete diagnostic procedures. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1472 RADIATOR FAN OPERATION CHART Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Removal and Installation Radiator Cooling Fan Motor: Service and Repair Removal and Installation 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 radiator upper hose level. 3. Remove radiator upper hose from radiator. 4. Disconnect radiator fan electrical connector. 5. Remove radiator fan screws from radiator. 6. Lift fan shroud up and out of lower shroud attachment clips. 7. For radiator fan assembly sub-component removal procedures Refer to RADIATOR FAN - DISASSEMBLY. INSTALLATION 1. Install the radiator fan assembly into the clips on the lower radiator tank. 2. Install the retaining screws and tighten to 7.5 Nm (65 inch lbs.). 3. Connect radiator fan electrical connector. 4. Connect the radiator upper hose. Align hose and position clamp to prevent interference with the engine or the hood. 5. Connect negative cable to battery. 6. Fill the cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Removal and Installation > Page 1475 Radiator Cooling Fan Motor: Service and Repair Disassembly and Assembly 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. 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Removal and Installation > Page 1476 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. 2. Install fan retaining nut and tighten to 3.8 Nm (34 inch lbs.)). 3. Install radiator fan assembly. FAN MOTOR 1. Install the fan motor on shroud and tighten screws to 3.8 Nm (34 inch lbs.). 2. Install screw attaching the in-rush current suppressor and tighten to 2.6 Nm (23 inch lbs.). 3. Install the fan on motor shaft. 4. Install the radiator fan assembly. SHROUD 1. Install the FAN MOTOR. 2. Install the FAN. 3. Install the radiator fan assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1480 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Radiator Fan Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1481 Power Distribution Center Radiator Fan Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1486 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1487 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1488 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1489 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions Heater Core: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 AIR-BAG 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement - LHD Heater Core: Service and Repair Heater Core Replacement - LHD REMOVAL For heater core removal procedure, Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair INSTALLATION For heater core installation procedure, Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement - LHD > Page 1495 Heater Core: Service and Repair Heater Core Replacement - RHD REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 AIR-BAG 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. 1. Disconnect the negative battery cable. 2. Drain the cooling system. 3. Evacuate the refrigerant system. 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 Fig.17 Expansion Valve Position And Orientation 5. Remove the refrigerant line retaining bolt from the expansion valve. Remove the refrigerant lines from the expansion valve. 6. Disconnect the electrical connector from the bottom of the expansion valve. 7. Remove the expansion valve retaining bolts and remove the valve from the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement - LHD > Page 1496 Fig.18 Heater Core Coolant Supply Lines 8. Remove the heater core coolant supply hoses from the heater core. 9. Working from inside the engine compartment, remove the A/C-Heater housing retaining fasteners from the bulkhead. 10. Remove the A/C-Heater housing drain tube. Remove the spring clip and pull the hose from the housing nipple. 11. Working from inside the vehicle, remove the defroster duct from the A/C-Heater housing and body attachment point. 12. Remove the A/C-Heater housing retaining bolts. 13. Disconnect the electrical connectors from the A/C-Heater housing. 14. Remove the A/C-Heater housing from the vehicle and place the assembly on a bench. 15. Remove the heater core cover from the housing assembly. 16. Remove the heater core coolant lines from the heater core. Fig.19 Heater A/C Housing Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement - LHD > Page 1497 17. Remove the screws necessary to disassemble the A/C-Heater housing assembly. 18. Remove the heater core from the A/C-Heater housing. INSTALLATION Fig.20 Heater A/C Housing 1. Install the heater core in the A/C-Heater housing. 2. Reassemble the A/C-Heater housing. 3. Install the housing in the vehicle and install the retaining bolts. Torque the bolts to 20 Nm (177 in. lbs.). 4. Connect the electrical connectors on the A/C- Heater housing. 5. Install the defroster duct on the A/C-Heater housing and secure at the body attachment point. 6. Install the A/C-Heater housing drain tube and retaining clip. 7. Install the A/C-Heater housing retaining fasteners. Torque the fasteners to 20 Nm (177 in. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement - LHD > Page 1498 Fig.21 Heater Core Coolant Supply Lines 8. Install the heater core coolant supply hoses on the heater core. 9. Install the expansion valve, gasket and retaining bolts. Torque the bolts to 11 Nm (97 in. lbs.). Fig.22 Expansion Valve Position And Orientation 10. Connect the electrical connector on the bottom of the expansion valve. CAUTION: Be certain the refrigerant line sealing O-rings are well lubricated and free of tears. 11. Install the refrigerant lines and retaining bolt. Torque the bolt to 23 Nm (203 in. lbs.). 12. 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 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. 15. Fill the cooling system . 16. Connect the negative battery cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL 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. 1. Drain engine cooling system. Refer to: "Cooling System : Service and Repair" See: Service and Repair Fig.23 Heater Hoses And Clamps 2. Using spring tension clamp pliers, remove clamps at end of heater hose to be removed. 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 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. 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Refer to: "Cooling System : Service and Repair" See: Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1504 Heater Hose: Service and Repair Heater Return Hose Replacement REMOVAL 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. 1. Drain engine cooling system. Refer to: "Cooling System : Service and Repair" See: Service and Repair Fig.24 Heater Hoses And Clamps 2. Using spring tension clamp pliers, 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. Refer to: "Cooling System : Service and Repair" See: Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1505 Heater Hose: Service and Repair Heater Tube Assembly Replacement REMOVAL 1. Disconnect negative battery cable. Disconnect positive battery cable. Remove battery. 2. Raise vehicle on hoist. 3. Drain cooling system . Refer to: "Cooling System : Service and Repair" See: Service and Repair 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. 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. Refer to: "Cooling System : Service and Repair" See: Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 inch lbs.). 3. Fill the cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing Radiator Cap: Testing and Inspection 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 radiator 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing > Page 1515 Radiator Cap: Testing and Inspection Radiator Cap Testing COOLING SYSTEM PRESSURE CAP TESTING 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 1516 Radiator Cap: Service and Repair CLEANING Use only a mild soap to clean the pressure cap. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1521 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Radiator Fan Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1522 Power Distribution Center Radiator Fan Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1528 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1529 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1530 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1531 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Opening Temperature ......................................................................................................................... ............................................ 195 Degrees Farenheit Full Opening Temperature ............................................................................................................................................................. 216 Degrees Farenheit Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1535 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1536 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. For other probable causes, Refer to Cooling System; Testing and Inspection. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1537 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 inch lbs.). 4. Install the radiator upper hose. 5. Connect the coolant recovery/reserve system hose. 6. Fill the cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1541 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1542 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1543 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(R) 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 inch lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1544 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 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 and access the "miscellaneous" screen. ^ Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 1549 Catalytic Converter: Description and Operation DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 1550 An under-floor catalytic converter is used on all three converter packages; National Low Emission Vehicle (NLEV), Ultra Low Emission Vehicle (ULEV), and the High Output engine. On the ULEV emission package, in addition to the under floor converter, a close-coupled catalytic converter is used. This converter is integral to the exhaust manifold 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 bellows or bellows cover of the flex-joint. Should this occur, the flex-joint will eventually fail and require the catalytic converter be replaced. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 1551 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 Powertrain Diagnostic Procedure for diagnosis of a catalyst related 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. The use of catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 1552 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. NOTE: Vehicles equipped with the ULEV emission package are equipped with an additional catalytic converter that is integral to the exhaust manifold. 1. Remove muffler and exhaust pipe. 2. Disconnect the downstream oxygen sensor electrical connector. 3. Remove the exhaust manifold support bracket (NLEV only). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 1553 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. Refer to Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove both oxygen sensors and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. 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 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 (NLEV only). Tighten M10 bolt to 54 Nm (40 ft. lbs.), M12 bolt to 95 Nm (70 ft. lbs.), and nut to 28 Nm (250 inch lbs.). 3. Install bolt attaching manifold support bracket to the heat shield (NLEV only). Tighten bolt to 28 Nm (250 inch 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 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Description and Operation > Exhaust Manifold - Standard Exhaust Manifold: Description and Operation Exhaust Manifold - Standard DESCRIPTION The exhaust manifold is made of nodular cast iron for strength and high temperatures. The manifold attaches to the cylinder head. OPERATION The exhaust manifold collects the exhaust gasses exiting the combustion chambers. Then it channels the exhaust gasses to the exhaust pipe attached to the manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Description and Operation > Exhaust Manifold - Standard > Page 1559 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Standard Exhaust Manifold: Service and Repair Exhaust Manifold - Standard 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 (NLEV) , or to the exhaust manifold (ULEV). 4. Remove exhaust manifold support bracket (NLEV). 5. Remove fasteners attaching exhaust system flex joint to exhaust manifold flange. Move exhaust system rearward to clear flange studs. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Standard > Page 1562 6. ULEV equipped-remove the support bracket from cylinder block to exhaust manifold. 7. Lower vehicle. 8. Disconnect make-up air hose from rear of cylinder head cover. 9. Remove speed control vacuum reservoir, if equipped. 10. Disconnect oxygen sensor connector and harness clip. 11. Remove heat shield attaching bolts. 12. Remove upper heat shield for access to manifold bolts. 13. Remove exhaust manifold bolts. 14. Remove the cylinder head cover, ULEV equipped only. Cover cylinder head opening with a suitable covering. 15. Remove exhaust manifold from top of vehicle, between the cylinder head and cowl. CLEANING 1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. INSPECTION 1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm. per 300 mm (0.006 in. per foot) of manifold length. 2. Inspect manifolds for cracks or distortion. Replace manifold as necessary INSTALLATION 1. Position exhaust manifold and gasket in place. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Standard > Page 1563 2. Install exhaust manifold bolts and tighten in sequence shown to 23 Nm (200 inch lbs.). 3. ULEV equipped-position upper heat shield on exhaust manifold. Install bolts and tighten to 23 Nm (200 inch lbs.). 4. Position lower and upper heat shield on exhaust manifold. Install heat shield bolts and tighten to 11 Nm (95 inch lbs.). 5. Connect oxygen sensor electrical connector and harness clip. 6. Install cylinder head cover (ULEV equipped). 7. Install speed control vacuum reservoir, if equipped. 8. Connect make-up air hose on cylinder head cover port. 9. Raise vehicle. 10. Install new flex joint to manifold flange gasket. 11. Attach exhaust system to manifold flange and tighten fasteners to 28 Nm (250 inch lbs.). 12. Install exhaust manifold support bracket and tighten fasteners (NLEV). 13. Install support bracket to cylinder block and exhaust manifold, if ULEV equipped. Snug all bolts first then tighten to 54 Nm (40 ft. lbs.). 14. Install bolt attaching wire harness heat shield to support bracket (NLEV), or exhaust manifold (ULEV). 15. Lower vehicle. 16. Connect negative cable to battery. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Standard > Page 1564 Exhaust Manifold: Service and Repair Exhaust Manifold - High Output 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. Remove speed control vacuum reservoir, if equipped. 9. Disconnect oxygen sensor connector and harness clip. 10. Remove heat shield attaching bolts. 11. Remove upper heat shield for access to manifold bolts. 12. Remove exhaust manifold bolts. 13. Remove exhaust manifold from top of vehicle, between the cylinder head and cowl. INSTALLATION 1. Position exhaust manifold and gasket in place. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Standard > Page 1565 2. Install exhaust manifold bolts and tighten in sequence shown to 23 Nm (200 inch lbs.). 3. Position lower and upper heat shield on exhaust manifold. Install heat shield bolts and tighten to 11 Nm (95 inch lbs.). 4. Connect oxygen sensor electrical connector and harness clip. 5. Install speed control vacuum reservoir, if equipped. 6. Connect make-up air hose on cylinder head cover port. 7. Raise vehicle. 8. Install new flex joint to manifold flange gasket. 9. Attach exhaust system to manifold flange and tighten fasteners to 28 Nm (250 inch lbs.). 10. Install exhaust manifold support bracket and tighten fasteners. 11. Install bolt attaching wire harness heat shield to support bracket. 12. Lower vehicle. 13. Connect negative cable to battery. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Band Clamps - Fasteners 35 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1569 Exhaust Pipe: 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 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1570 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. NOTE: Maintain proper clamp orientation when replacing with new clamp. 5. Connect the exhaust system ground strap. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1574 Heat Shield: Service and Repair REMOVAL 1. Raise vehicle on hoist. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1575 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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. NOTE: Maintain proper clamp orientation when replacing with new clamp. 4. Connect the exhaust system ground strap. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation, this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set making diagnosis of the original problem more difficult. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation Body Control Module: Description and Operation System Description and Functional Operation SYSTEM DESCRIPTION The body system on the 2001 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 of this general information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1587 Body Control Module: Description and Operation Functional Operation Part 1 of 2 FUNCTIONAL OPERATION 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 micro-processor 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. Driver Airbag Module (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. THE AIRBAG MODULE 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1588 Passenger Airbag Module (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. THE AIRBAG MODULE 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 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). 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 Airbag Modules 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. THE SEAT 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). 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. ACM/SIACM 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1589 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 minmum 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. AUDIO SYSTEM The audio system on the 2001 PL consists of a radio that communicates over the PCI bus. Each radio system comes equipped with a standard premium 6 speaker system. 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. Depending on the manufacture, some systems will have Front/Rear output system and others will have a Left/Right output system. 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 can display, indicating which output is effected. 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. Part 2 of 2 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) For the domestic market there are 2 (two) Instrument Cluster types, Base and Premium. The Premium Instrument Cluster is equipped with a Tachometer and a Low Fuel indicator. 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 to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1590 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. INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. The instrument cluster is sometimes referred to as a "Smart Cluster Control Module". 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. 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Vehicle Theft Security System The VTSS monitors the vehicle doors, decklid, hood and the ignition for unauthorized operation. Additionally, the decklid key cylinder is monitored for tampering, such as attempts to punch out the key cylinder. The alarm activates by sounding the horn, flashing the headlamps, park lamps and the VTSS indicator in the instrument cluster. Locking the doors with the door lock switch (through following a normal exit sequence of opening the door, pressing the lock button, and closing the door), the door cylinder lock switches or the RKE transmitter arms the system. During the 16 second arming process the VTSS indicator will flash quickly and when the system is armed will slow down. THE SYSTEM WILL NOT ARM IF THE HOOD IS OPEN (switch is grounded), or the decklid security switch (knockout) is not grounded, the LED will stay ON steady during arming. The engine kill feature on domestic vehicles is accomplished via the Sentry Key Immobilizer Module (SKIM). All of the sensors for the VTS 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. Power Door Locks Central Locking This feature allows the customer to lock/unlock all vehicle doors with the key from either front door cylinder lock switch. The customer can choose to program this feature to unlock all doors with one turn of the key or open the driver door only with the first turn of the key and open the other doors with the second turn. Altering the operation of the unlock function via the key cylinder switch from one turn to two turns will also alter the operation of the RKE transmitter from one press to two presses. Rolling (Automatic) Door Locks All vehicle doors are locked automatically once the vehicle reaches a speed of 15 mph and all doors are closed. This feature can be also be enabled! disabled by the customer. Door Lock Inhibit This feature disables the door lock command from the interior door lock switch whenever the driver door is open and the key is in the ignition. This prevents the driver from locking the keys in the ignition when using the power door locks. This feature is inoperable if the IOD fuse is not installed. Power Decklid Release Electrically releases the decklid upon two presses of the RKE transmitter decklid release button. This feature is disabled once the speed of the vehicle is greater than 5 mph. This feature may be altered with the DRB III to allow the decklid to be released with one press of the RKE transmitter decklid release button. The decklid can also be released from the switch in the glove box. Panic Mode Upon activation of the panic function, the headlamps and park lamps flash in an alternating manner, the horn pulses every second and the courtesy lamps are turned ON. The panic mode allow normal nighttime driving by allowing the headlamps and park lamps to be on steady when the headlamp switch is in the ON position. Panic mode is activated immediately by pressing the panic button once. It does not disarm the VTSS or unlock the doors. It is canceled by pressing the button a second time, reaching a vehicle speed greater than 15 mph or after 3 minutes has elapsed in panic mode. Once panic mode has been activated there is a 2-second delay before it will turn OFF. Once it is cancelled there is a 2-second delay before it can be reactivated. This is to avoid the problem of deactivating and immediate reactivating due to multiple Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1591 button presses. 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 and is violet with a yellow tracer. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2001 PL: Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio - CD Changer - Remote Keyless Entry Module - Sentry Key Immobilizer Module - Transmission Control 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1592 are transmitting and is pulled up to about seven and a half volts when modules are transmitting. 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 12V 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 figure 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 module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 1593 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 +/- 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle 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. 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Component Tests and General Diagnostics > Page 1596 Body Control Module: Scan Tool Testing and Procedures 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Component Tests and General Diagnostics > Page 1597 Down or Page Up function to display the information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1598 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Test Light Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure Powertrain Control Module: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 1603 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 1604 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 1605 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1606 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws ................................................................................................................................4 Nm (35 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1607 Powertrain Control Module: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1610 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1611 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1612 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1613 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1614 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1615 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1616 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1617 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1618 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1619 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1620 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 Powertrain Control Module: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2000 PL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1633 Powertrain Control Module: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1634 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1635 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1639 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1640 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1641 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1642 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1643 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1644 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center The fuel pump relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1649 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1650 Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1651 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 also protects the power circuit for the Automatic Shutdown (ASD) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1655 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1656 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1657 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1658 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1659 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1660 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 1664 Manifold Tuning Valve Relay: Diagrams Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 1665 Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1674 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1675 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1676 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1677 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1678 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1682 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1683 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1684 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1685 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1689 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1690 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1691 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1692 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1693 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1697 Fuel Level Sensor: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1698 Fuel Level Sensor: Service and Repair 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. 5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1699 Fig. 6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 7 Level Sensor 5. Slide level sensor wires through opening fuel pump module. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications Intake Air Temperature (IAT) Sensor: Specifications MAP/IAT Sensor Plastic Manifold......................................................................................................... ......................................................2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1703 Intake Air Temperature (IAT) Sensor: Locations Fig. 16 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1704 Inlet Air Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 1705 Intake Air Temperature (IAT) Sensor: Description and Operation Fig. 16 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 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1709 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1710 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1711 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1712 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor ........................................................................................................................................ .................................................... 4.5 Nm (40 in. lbs) MAP/IAT Sensor (plastic manifold) .......................................................................................................................................................... 2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1716 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1717 Manifold Absolute Pressure Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1718 Manifold Absolute Pressure (MAP) Sensor: Description and Operation Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezoresistive 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1719 - Decel fuel shutoff 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1720 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 22 MAP Sensor REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 28 Nm (20 ft. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 26 Types Or O2 Sensors Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 1729 Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Fig. 24 Downstream Heated Oxygen Sensor 1/2 The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 1730 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1731 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1732 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1733 Oxygen Sensor: Description and Operation Fig. 26 Types Or O2 Sensors Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1734 Fig. 24 Downstream Heated Oxygen Sensor 1/2 Fig. 25 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. Separate controlled ground circuits are run through the PCM for the upstream O2 sensors. 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), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1735 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement Oxygen Sensor: Service and Repair Downstream 1/2 Replacement REMOVAL Fig. 28 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. 29 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 The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement > Page 1738 2. Connect sensor electrical harness from clips along body. 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement > Page 1739 Oxygen Sensor: Service and Repair Upstream 1/1 Replacement REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig. 27 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1743 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1744 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1745 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1746 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1750 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1751 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1752 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1753 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1757 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1758 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1759 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1760 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt ...................................................................................................................................................2.2 Nm (19.4 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 1764 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 Vehicle Speed Sensor: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Vehicle Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 Vehicle Speed Sensor: Service and Repair Manual Transmission A578 VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector. 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. 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. 2. Using a NEW O-ring, install the speed sensor to the transaxle. 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector. 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 > Page 1788 Vehicle Speed Sensor: Service and Repair Automatic Transmission 31TH VEHICLE SPEED SENSOR/ PINION GEAR REMOVAL 1. Remove harness connector from sensor. Be sure weather seal stays on harness connector. 2. Remove bolt securing the sensor in the extension housing. 3. Carefully pull sensor and pinion gear assembly out of extension housing. 4. Remove pinion gear from sensor. 5. Inspect pinion gear for damage (missing teeth, etc.) and replace as necessary. NOTE: When removing vehicle speed sensor for any reason, a new O-ring MUST be used. INSTALLATION 1. Install vehicle speed sensor and pinion gear to extension housing with new O-ring. 2. Install bolt and torque to 7 Nm (60 inch lbs.). 3. Connect connector. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1793 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1794 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1795 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1796 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1801 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1802 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1803 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1804 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1805 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1809 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1810 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1811 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1812 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1813 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1822 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1823 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1824 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1825 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1831 Fuel Pressure: Specifications Fuel System Volume Fuel System Volume Volume 1/4 Liter (1/2 pint) in 7 seconds Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1832 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1833 Tests 3 - 5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1834 Tests 6 - 10 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 pump capacity (volume) out of specs - Fuel pump relay fused B+ circuit - Fuel pump relay output circuit open Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1835 - Fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 600-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test, using a scan tool. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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. 9). 2. Install lid and tighten screws. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1847 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1852 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1853 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE.................................................................................................................................................. ............................................................RESISTANCE #1 #4..................................................................................................................................................... ............................................. 3500 ohms - 4900 ohms #2 #3..................................................................................................................................................... ............................................. 2950 ohms - 4100 ohms Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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(R) parts cleaner or equivalent. 2. Apply Mopar(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1868 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1872 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. Disconnect the ignition coil electrical connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications MAP/IAT Sensor Plastic Manifold......................................................................................................... ......................................................2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1880 Intake Air Temperature (IAT) Sensor: Locations Fig. 16 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1881 Inlet Air Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1882 Intake Air Temperature (IAT) Sensor: Description and Operation Fig. 16 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 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation, this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set making diagnosis of the original problem more difficult. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation Body Control Module: Description and Operation System Description and Functional Operation SYSTEM DESCRIPTION The body system on the 2001 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 of this general information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1891 Body Control Module: Description and Operation Functional Operation Part 1 of 2 FUNCTIONAL OPERATION 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 micro-processor 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. Driver Airbag Module (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. THE AIRBAG MODULE 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1892 Passenger Airbag Module (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. THE AIRBAG MODULE 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 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). 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 Airbag Modules 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. THE SEAT 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). 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. ACM/SIACM 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1893 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 minmum 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. AUDIO SYSTEM The audio system on the 2001 PL consists of a radio that communicates over the PCI bus. Each radio system comes equipped with a standard premium 6 speaker system. 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. Depending on the manufacture, some systems will have Front/Rear output system and others will have a Left/Right output system. 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 can display, indicating which output is effected. 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. Part 2 of 2 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) For the domestic market there are 2 (two) Instrument Cluster types, Base and Premium. The Premium Instrument Cluster is equipped with a Tachometer and a Low Fuel indicator. 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 to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1894 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. INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. The instrument cluster is sometimes referred to as a "Smart Cluster Control Module". 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. 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Vehicle Theft Security System The VTSS monitors the vehicle doors, decklid, hood and the ignition for unauthorized operation. Additionally, the decklid key cylinder is monitored for tampering, such as attempts to punch out the key cylinder. The alarm activates by sounding the horn, flashing the headlamps, park lamps and the VTSS indicator in the instrument cluster. Locking the doors with the door lock switch (through following a normal exit sequence of opening the door, pressing the lock button, and closing the door), the door cylinder lock switches or the RKE transmitter arms the system. During the 16 second arming process the VTSS indicator will flash quickly and when the system is armed will slow down. THE SYSTEM WILL NOT ARM IF THE HOOD IS OPEN (switch is grounded), or the decklid security switch (knockout) is not grounded, the LED will stay ON steady during arming. The engine kill feature on domestic vehicles is accomplished via the Sentry Key Immobilizer Module (SKIM). All of the sensors for the VTS 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. Power Door Locks Central Locking This feature allows the customer to lock/unlock all vehicle doors with the key from either front door cylinder lock switch. The customer can choose to program this feature to unlock all doors with one turn of the key or open the driver door only with the first turn of the key and open the other doors with the second turn. Altering the operation of the unlock function via the key cylinder switch from one turn to two turns will also alter the operation of the RKE transmitter from one press to two presses. Rolling (Automatic) Door Locks All vehicle doors are locked automatically once the vehicle reaches a speed of 15 mph and all doors are closed. This feature can be also be enabled! disabled by the customer. Door Lock Inhibit This feature disables the door lock command from the interior door lock switch whenever the driver door is open and the key is in the ignition. This prevents the driver from locking the keys in the ignition when using the power door locks. This feature is inoperable if the IOD fuse is not installed. Power Decklid Release Electrically releases the decklid upon two presses of the RKE transmitter decklid release button. This feature is disabled once the speed of the vehicle is greater than 5 mph. This feature may be altered with the DRB III to allow the decklid to be released with one press of the RKE transmitter decklid release button. The decklid can also be released from the switch in the glove box. Panic Mode Upon activation of the panic function, the headlamps and park lamps flash in an alternating manner, the horn pulses every second and the courtesy lamps are turned ON. The panic mode allow normal nighttime driving by allowing the headlamps and park lamps to be on steady when the headlamp switch is in the ON position. Panic mode is activated immediately by pressing the panic button once. It does not disarm the VTSS or unlock the doors. It is canceled by pressing the button a second time, reaching a vehicle speed greater than 15 mph or after 3 minutes has elapsed in panic mode. Once panic mode has been activated there is a 2-second delay before it will turn OFF. Once it is cancelled there is a 2-second delay before it can be reactivated. This is to avoid the problem of deactivating and immediate reactivating due to multiple Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1895 button presses. 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 and is violet with a yellow tracer. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2001 PL: Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio - CD Changer - Remote Keyless Entry Module - Sentry Key Immobilizer Module - Transmission Control 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1896 are transmitting and is pulled up to about seven and a half volts when modules are transmitting. 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 12V 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 figure 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 module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 1897 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 +/- 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle 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. 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 1900 Body Control Module: Scan Tool Testing and Procedures 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 1901 Down or Page Up function to display the information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 1902 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Test Light Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1906 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1907 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1908 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1909 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1910 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1914 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1915 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1916 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1917 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1921 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1922 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1923 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1924 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 1925 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 Data Link Connector: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1947 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1948 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1949 Data Link Connector: Connector Views Data Link Connector Data Link Connector Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 1950 Data Link Connector: Description and Operation Fig.2 Data Link Connector 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Powertrain Control Module: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1955 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1956 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1957 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1958 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws ................................................................................................................................4 Nm (35 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1959 Powertrain Control Module: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 Powertrain Control Module: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2000 PL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1985 Powertrain Control Module: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1986 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 1987 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1991 Fuel Level Sensor: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1992 Fuel Level Sensor: Service and Repair 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. 5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1993 Fig. 6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 7 Level Sensor 5. Slide level sensor wires through opening fuel pump module. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications IAC Motor-To-Throttle Body Bolts ....................................................................................................... ...................................................4.5 Nm (40 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 1997 Idle Air Control (IAC) Motor: Locations Fig. 14 Idle Air Control Motor - Typical The Idle Air Control (IAC) motor is mounted on the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 1998 Idle Air Control Motor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 1999 Idle Air Control (IAC) Motor: Description and Operation Fig. 14 Idle Air Control Motor - Typical The Idle Air Control (IAC) motor is mounted on the throttle body. The PCM operates the idle air control motor. It is an electric stepper motor. The PCM adjusts engine idle speed through the idle air control motor 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 motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor 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). 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2000 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. 15 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 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2005 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2006 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2007 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2008 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2009 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2010 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 Information Bus: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 Information Bus: Electrical Diagrams Vehicle Communication Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 PCM Communication Wiring Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 8w-18-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 8w-18-3 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Brief Description Information Bus: Description and Operation Brief Description 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 - Air Bag System Diagnostic Module - Full ATC Display Head - ABS Module - Transmission Control Module - Powertrain Control Module - Overhead Travel Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Brief Description > Page 2029 Information Bus: Description and Operation Detailed Description PROGRAMMABLE COMMUNICATION INTERFACE (PCI) BUS The Programmable Communication Interface (PCI) data bus is a single wire multiplexed network used for vehicle communications on many DaimlerChrysler Corporation vehicles. Multiplexing is a system that enables the transmission of several messages over a single channel or circuit between various microprocessor-based electronic control modules. The PCI data bus exceeds the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. 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 hard-ware, 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 binary encoded messages over a single wire broadcast network. The PCI bus circuit is identified as D25 and 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 modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2001 Neon: - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio - CD Changer - Remote Keyless Entry Module - Sentry Key Immobilizer Module - Transmission Control Module (If equipped) - Mechanical Instrument Cluster Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Brief Description > Page 2030 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 (Kips). By comparison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kips. 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 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. The preferred method is to use the DRB III lab scope function. The 12V 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 figure for some typical displays. 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. 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. 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 zero volts and the high voltage is about seven and one-half 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Brief Description > Page 2031 "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. 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 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 module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC 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 +/- 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2035 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2036 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2037 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2038 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2042 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2043 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2044 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2045 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2046 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2047 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Application and ID > Page 2051 Malfunction Indicator Lamp: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor ........................................................................................................................................ .................................................... 4.5 Nm (40 in. lbs) MAP/IAT Sensor (plastic manifold) .......................................................................................................................................................... 2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2055 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2056 Manifold Absolute Pressure Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2057 Manifold Absolute Pressure (MAP) Sensor: Description and Operation Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezoresistive 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2058 - Decel fuel shutoff 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2059 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 22 MAP Sensor REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 28 Nm (20 ft. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 26 Types Or O2 Sensors Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2068 Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Fig. 24 Downstream Heated Oxygen Sensor 1/2 The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2069 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2070 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2071 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2072 Oxygen Sensor: Description and Operation Fig. 26 Types Or O2 Sensors Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2073 Fig. 24 Downstream Heated Oxygen Sensor 1/2 Fig. 25 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. Separate controlled ground circuits are run through the PCM for the upstream O2 sensors. 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), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2074 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream 1/2 Replacement Oxygen Sensor: Service and Repair Downstream 1/2 Replacement REMOVAL Fig. 28 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. 29 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 The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream 1/2 Replacement > Page 2077 2. Connect sensor electrical harness from clips along body. 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream 1/2 Replacement > Page 2078 Oxygen Sensor: Service and Repair Upstream 1/1 Replacement REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig. 27 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2082 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2083 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2084 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2085 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation, this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set making diagnosis of the original problem more difficult. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation Body Control Module: Description and Operation System Description and Functional Operation SYSTEM DESCRIPTION The body system on the 2001 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 of this general information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2092 Body Control Module: Description and Operation Functional Operation Part 1 of 2 FUNCTIONAL OPERATION 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 micro-processor 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. Driver Airbag Module (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. THE AIRBAG MODULE 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2093 Passenger Airbag Module (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. THE AIRBAG MODULE 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 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). 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 Airbag Modules 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. THE SEAT 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). 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. ACM/SIACM 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2094 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 minmum 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. AUDIO SYSTEM The audio system on the 2001 PL consists of a radio that communicates over the PCI bus. Each radio system comes equipped with a standard premium 6 speaker system. 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. Depending on the manufacture, some systems will have Front/Rear output system and others will have a Left/Right output system. 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 can display, indicating which output is effected. 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. Part 2 of 2 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) For the domestic market there are 2 (two) Instrument Cluster types, Base and Premium. The Premium Instrument Cluster is equipped with a Tachometer and a Low Fuel indicator. 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 to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2095 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. INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. The instrument cluster is sometimes referred to as a "Smart Cluster Control Module". 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. 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Vehicle Theft Security System The VTSS monitors the vehicle doors, decklid, hood and the ignition for unauthorized operation. Additionally, the decklid key cylinder is monitored for tampering, such as attempts to punch out the key cylinder. The alarm activates by sounding the horn, flashing the headlamps, park lamps and the VTSS indicator in the instrument cluster. Locking the doors with the door lock switch (through following a normal exit sequence of opening the door, pressing the lock button, and closing the door), the door cylinder lock switches or the RKE transmitter arms the system. During the 16 second arming process the VTSS indicator will flash quickly and when the system is armed will slow down. THE SYSTEM WILL NOT ARM IF THE HOOD IS OPEN (switch is grounded), or the decklid security switch (knockout) is not grounded, the LED will stay ON steady during arming. The engine kill feature on domestic vehicles is accomplished via the Sentry Key Immobilizer Module (SKIM). All of the sensors for the VTS 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. Power Door Locks Central Locking This feature allows the customer to lock/unlock all vehicle doors with the key from either front door cylinder lock switch. The customer can choose to program this feature to unlock all doors with one turn of the key or open the driver door only with the first turn of the key and open the other doors with the second turn. Altering the operation of the unlock function via the key cylinder switch from one turn to two turns will also alter the operation of the RKE transmitter from one press to two presses. Rolling (Automatic) Door Locks All vehicle doors are locked automatically once the vehicle reaches a speed of 15 mph and all doors are closed. This feature can be also be enabled! disabled by the customer. Door Lock Inhibit This feature disables the door lock command from the interior door lock switch whenever the driver door is open and the key is in the ignition. This prevents the driver from locking the keys in the ignition when using the power door locks. This feature is inoperable if the IOD fuse is not installed. Power Decklid Release Electrically releases the decklid upon two presses of the RKE transmitter decklid release button. This feature is disabled once the speed of the vehicle is greater than 5 mph. This feature may be altered with the DRB III to allow the decklid to be released with one press of the RKE transmitter decklid release button. The decklid can also be released from the switch in the glove box. Panic Mode Upon activation of the panic function, the headlamps and park lamps flash in an alternating manner, the horn pulses every second and the courtesy lamps are turned ON. The panic mode allow normal nighttime driving by allowing the headlamps and park lamps to be on steady when the headlamp switch is in the ON position. Panic mode is activated immediately by pressing the panic button once. It does not disarm the VTSS or unlock the doors. It is canceled by pressing the button a second time, reaching a vehicle speed greater than 15 mph or after 3 minutes has elapsed in panic mode. Once panic mode has been activated there is a 2-second delay before it will turn OFF. Once it is cancelled there is a 2-second delay before it can be reactivated. This is to avoid the problem of deactivating and immediate reactivating due to multiple Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2096 button presses. 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 and is violet with a yellow tracer. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2001 PL: Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio - CD Changer - Remote Keyless Entry Module - Sentry Key Immobilizer Module - Transmission Control 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2097 are transmitting and is pulled up to about seven and a half volts when modules are transmitting. 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 12V 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 figure 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 module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 and Functional Operation > Page 2098 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 +/- 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle 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. 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2101 Body Control Module: Scan Tool Testing and Procedures 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2102 Down or Page Up function to display the information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2103 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Test Light Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure Powertrain Control Module: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 2108 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 2109 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Engine Control - PCM Initialization Procedure > Page 2110 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2111 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Mounting Screws ................................................................................................................................4 Nm (35 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2112 Powertrain Control Module: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Powertrain Control Module: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Powertrain Control Module C1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 Powertrain Control Module C2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2000 PL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2138 Powertrain Control Module: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2139 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2140 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2144 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2145 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2146 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2147 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2148 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2149 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2157 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2158 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2159 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2160 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2161 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2165 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2166 Engine Coolant Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2167 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The coolant 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), dual range 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 low and high speed radiator cooling fans. OPERATION The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air- fuel mixtures and higher idle speeds until normal operating temperatures are reached. The PCM has a dual temperature range program for better sensor accuracy at cold temperatures. At key-ON the PCM sends a regulated five volt signal through a 10,000 ohm resistor to the sensor. When the sensed voltage reaches approximately 1.25 volts the PCM turns on the transistor. The transistor connects a 1,000 ohm resistor in parallel with the 10,000 ohm resistor. With this drop in resistance the PCM recognizes an increase in voltage on the input circuit. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2168 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 inch lbs.) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2172 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2173 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2174 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2175 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2176 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2180 Fuel Level Sensor: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2181 Fuel Level Sensor: Service and Repair 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. 5 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2182 Fig. 6 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 7 Level Sensor 5. Slide level sensor wires through opening fuel pump module. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications Intake Air Temperature (IAT) Sensor: Specifications MAP/IAT Sensor Plastic Manifold......................................................................................................... ......................................................2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 2186 Intake Air Temperature (IAT) Sensor: Locations Fig. 16 Inlet Air Temperature Sensor The IAT sensor attaches to the intake air duct. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 2187 Inlet Air Temperature Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Specifications > Page 2188 Intake Air Temperature (IAT) Sensor: Description and Operation Fig. 16 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 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2192 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2193 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2194 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2195 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor ........................................................................................................................................ .................................................... 4.5 Nm (40 in. lbs) MAP/IAT Sensor (plastic manifold) .......................................................................................................................................................... 2 Nm (20 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2199 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2200 Manifold Absolute Pressure Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2201 Manifold Absolute Pressure (MAP) Sensor: Description and Operation Fig. 21 Manifold Absolute Pressure Sensor The MAP sensor mounts to the intake manifold. The MAP sensor signal is provided from a single piezoresistive 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2202 - Decel fuel shutoff 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2203 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 22 MAP Sensor REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Engine Oil Pressure Switch Engine Oil Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 28 Nm (20 ft. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 26 Types Or O2 Sensors Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2212 Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Fig. 24 Downstream Heated Oxygen Sensor 1/2 The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2213 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2214 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2215 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2216 Oxygen Sensor: Description and Operation Fig. 26 Types Or O2 Sensors Fig. 23 Upstream Heated Oxygen Sensor 1/1 The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2217 Fig. 24 Downstream Heated Oxygen Sensor 1/2 Fig. 25 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. Separate controlled ground circuits are run through the PCM for the upstream O2 sensors. 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), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2218 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement Oxygen Sensor: Service and Repair Downstream 1/2 Replacement REMOVAL Fig. 28 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. 29 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 The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement > Page 2221 2. Connect sensor electrical harness from clips along body. 3. Connect electrical connector to harness. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Replacement > Page 2222 Oxygen Sensor: Service and Repair Upstream 1/1 Replacement REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. Fig. 27 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2226 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2227 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2228 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2229 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2233 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2234 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2235 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2236 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2240 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2241 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2242 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2243 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt ...................................................................................................................................................2.2 Nm (19.4 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2247 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 Vehicle Speed Sensor: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 Vehicle Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 Vehicle Speed Sensor: Service and Repair Manual Transmission A578 VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector. 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. 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. 2. Using a NEW O-ring, install the speed sensor to the transaxle. 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector. 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 > Page 2271 Vehicle Speed Sensor: Service and Repair Automatic Transmission 31TH VEHICLE SPEED SENSOR/ PINION GEAR REMOVAL 1. Remove harness connector from sensor. Be sure weather seal stays on harness connector. 2. Remove bolt securing the sensor in the extension housing. 3. Carefully pull sensor and pinion gear assembly out of extension housing. 4. Remove pinion gear from sensor. 5. Inspect pinion gear for damage (missing teeth, etc.) and replace as necessary. NOTE: When removing vehicle speed sensor for any reason, a new O-ring MUST be used. INSTALLATION 1. Install vehicle speed sensor and pinion gear to extension housing with new O-ring. 2. Install bolt and torque to 7 Nm (60 inch lbs.). 3. Connect connector. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2275 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2276 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2277 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2278 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2282 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2283 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2284 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2285 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt ...................................................................................................................................................2.2 Nm (19.4 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2289 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Vehicle Speed Sensor: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 Vehicle Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 Vehicle Speed Sensor: Service and Repair Manual Transmission A578 VEHICLE SPEED SENSOR REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the speed sensor connector. 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. 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. 2. Using a NEW O-ring, install the speed sensor to the transaxle. 3. Install the bolt and torque to 7 Nm (60 inch lbs.). 4. Connect speed sensor connector. 5. Lower vehicle and road test to verify proper speedometer operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission A578 > Page 2313 Vehicle Speed Sensor: Service and Repair Automatic Transmission 31TH VEHICLE SPEED SENSOR/ PINION GEAR REMOVAL 1. Remove harness connector from sensor. Be sure weather seal stays on harness connector. 2. Remove bolt securing the sensor in the extension housing. 3. Carefully pull sensor and pinion gear assembly out of extension housing. 4. Remove pinion gear from sensor. 5. Inspect pinion gear for damage (missing teeth, etc.) and replace as necessary. NOTE: When removing vehicle speed sensor for any reason, a new O-ring MUST be used. INSTALLATION 1. Install vehicle speed sensor and pinion gear to extension housing with new O-ring. 2. Install bolt and torque to 7 Nm (60 inch lbs.). 3. Connect connector. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Application and ID Voltage Signal: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Voltage Indicator................................................................................................................................... ..................................................................LED Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 2321 Catalytic Converter: Description and Operation DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 2322 An under-floor catalytic converter is used on all three converter packages; National Low Emission Vehicle (NLEV), Ultra Low Emission Vehicle (ULEV), and the High Output engine. On the ULEV emission package, in addition to the under floor converter, a close-coupled catalytic converter is used. This converter is integral to the exhaust manifold 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 bellows or bellows cover of the flex-joint. Should this occur, the flex-joint will eventually fail and require the catalytic converter be replaced. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 2323 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 Powertrain Diagnostic Procedure for diagnosis of a catalyst related 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. The use of catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 2324 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. NOTE: Vehicles equipped with the ULEV emission package are equipped with an additional catalytic converter that is integral to the exhaust manifold. 1. Remove muffler and exhaust pipe. 2. Disconnect the downstream oxygen sensor electrical connector. 3. Remove the exhaust manifold support bracket (NLEV only). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 2325 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. Refer to Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove both oxygen sensors and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. 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 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 (NLEV only). Tighten M10 bolt to 54 Nm (40 ft. lbs.), M12 bolt to 95 Nm (70 ft. lbs.), and nut to 28 Nm (250 inch lbs.). 3. Install bolt attaching manifold support bracket to the heat shield (NLEV only). Tighten bolt to 28 Nm (250 inch 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 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations EVAP Purge Solenoid / Power Steering Switch Fig. 2 Proportional Purge Solenoid Valve The solenoid attaches to a bracket near the steering gear. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2330 Canister Purge Solenoid: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2331 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. 1. Raise vehicle and support. 2. Disconnect electrical connector from solenoid. 3. Disconnect vacuum tubes from solenoid. 4. Remove solenoid from bracket. INSTALLATION 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. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. 4. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Fig. 9 EVAP Canister The vacuum and vapor tubes connect to the top of the canister. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2335 Evaporative Emission Control Canister: Description and Operation VAPOR CANISTER Fig. 9 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2336 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Raise vehicle and support. Fig. 10 EVAP Canister 3. Disconnect the hoses from the EVAP canister. Fig. 11 EVAP 4. Remove 1 nuts from the bracket of the EVAP canister. 5. Remove EVAP canister from bracket. INSTALLATION 1. Install EVAP canister to Bracket Fig. 11). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest for Leak Detection Pump: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Leak Detection Pump: Customer Interest Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest for Leak Detection Pump: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 2345 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Leak Detection Pump: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Leak Detection Pump: All Technical Service Bulletins Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Leak Detection Pump: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 2351 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2352 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2353 Leak Detection Pump (Except Built-Up-Export) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2354 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2355 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2356 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2357 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2358 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2359 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2360 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2361 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2362 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2363 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.). 3. 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. NOTE: The LOP bracket must be between the rail and away bar bracket. 4. Install pump and bracket assembly to body and tighten bolts to 5.0 Nm (45 in. lbs.). 5. Install sway bar bracket bolt and tighten bolts to 33.8 Nm (25 ft. lbs.). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2368 Positive Crankcase Ventilation Valve: Description and Operation Fig. 5 PCV System Fig. 6 Engine OFF Or Engine Backfire No Vapor Flow This is a valve screwed into the engine valve cover. When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. Fig. 7 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2369 Fig. 8 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure > Page 2375 Fuel Pressure: Specifications Fuel System Volume Fuel System Volume Volume 1/4 Liter (1/2 pint) in 7 seconds Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2376 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2377 Tests 3 - 5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2378 Tests 6 - 10 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 pump capacity (volume) out of specs - Fuel pump relay fused B+ circuit - Fuel pump relay output circuit open Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2379 - Fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 2383 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 600-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test, using a scan tool. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal to Dash Nuts ............................................................................................................................................12 Nm (8.8 ft. lbs) (105 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2390 Accelerator Pedal: Service Precautions CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2391 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2392 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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. 9). 2. Install lid and tighten screws. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Octane Ratings Fuel Octane Ratings 2.0 Standard Engine Minimum Octane Rating of 87 2.0 High Output Engine Preferred Octang Rating of 91 A minimum octane rating of 87 can safely be usue in this application, however, reduced acceleration may occur. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Page 2400 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations Fuel Filler Cap: Locations The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations > Page 2404 Fuel Filler Cap: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2409 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. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Description and Operation Fuel Hose Clamp: Description and Operation FUEL LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. 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. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Description and Operation > Page 2413 Fuel Hose Clamp: Service and Repair Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI. When installing hoses, ensure that they are routed away from contact with other vehicle components that could rub against them and cause failure. Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources. The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and cause high pressure fuel leaks. Tighten hose clamps to 1 Nm (10 in. lbs.) torque. Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of degradation that could result in failure. Never attempt to repair a plastic fuel line/tube. Replace as necessary. Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Resistance 10 - 16 Ohms At 68 degrees F (20 degrees C) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2417 Fuel Injector: Locations Fig. 7 Fuel Injector Location - Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 7). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2418 Fuel Injector: Diagrams Fuel Injector No.1 Fuel Injector No.2 Fuel Injector No.3 Fuel Injector No.4 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2419 Fuel Injector: Description and Operation Fig. 7 Fuel Injector Location - Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 7). Fig. 8 Fuel Injector Typical The fuel injectors are electrical solenoids (Fig. 8). 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. Fuel injectors are fired one crankshaft revolution before TDC compression. When cylinder # 4 is at TDC compression the injector for cylinder # 1 will be energized. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Injector Connector Replacement Fuel Injector: Service and Repair Injector Connector Replacement REMOVAL Fig. 9 Fuel Injectors Fig. 10 Remove/Install Injector Connector 1. Disconnect electrical connectors at the fuel injectors (Fig. 9). To remove connector refer to (Fig. 10). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Injector Connector Replacement > Page 2422 Fuel Injector: Service and Repair Fuel Injector Replacement REMOVAL 1. Disconnect negative cable from battery. 2. Remove fuel rail cover. 3. Release fuel system pressure. Refer to Fuel System Pressure Release procedure. 4. Disconnect fuel supply tube from rail. Refer to Quick-Connect Fittings in the Fuel Delivery. Fig. 11 Fuel Rail And Injectors 5. Disconnect electrical connectors from fuel injectors (Fig. 11), refer to the fuel injector connector for electrical connector removal. 6. Remove fuel rail mounting screws. 7. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. Fig. 12 Fuel Injector Retainer 8. Remove fuel injector retainer (Fig. 12). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Injector Connector Replacement > Page 2423 Fig. 13 Fuel Injector O-Rings 9. Pull injector out of fuel rail. Replace fuel injector O-rings (Fig. 13). 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. 'lighten fuel rail mounting screws to 22.5 Nm ±3 Nm (200 ±30 in. lbs.). 6. Attach electrical connectors to fuel injectors, refer to the fuel injector connector for electrical connector installation. 7. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings. 8. Install fuel rail cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information Fuel Line Coupler: Technician Safety Information WARNING: - RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. - 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. CAUTION: - Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. - 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information > Page 2429 Fuel Line Coupler: Vehicle Damage Warnings 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2430 Fuel Line Coupler: Description and Operation FUEL LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. 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. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Quick Connect Fitting Service QUICK CONNECT FITTING 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 quick-connect 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. 23 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. 23). 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 DRB III scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Service > Page 2433 Fuel Line Coupler: Service and Repair Two-Tab Type Fitting Service TWO-TAB TYPE FITTING Fig. 24 Typical Two-Tab Type Quick-Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting (Fig. 24). 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. DISCONNECTION / CONNECTION 1. Perform 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 disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 24) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Service > Page 2434 Fuel Line Coupler: Service and Repair Plastic Retainer Ring Type Fitting Service PLASTIC RETAINER RING TYPE FITTING Fig. 25 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 25) 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. 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. 25). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2438 Fuel Pressure Regulator: Service Precautions 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2439 Fuel Pressure Regulator: Description and Operation FUEL FILTER/FUEL PRESSURE REGULATOR Fig. 1 Side View - Filter/Regulator A combination fuel filter and fuel pressure regulator is used on all gas powered engines. It is located on the top of the fuel pump module. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of approximately 400 kPa ±34 kpa (58 psi ±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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2440 Fig. 8 Side View - Filter/Regulator It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 8) is also part of the assembly. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of approximately 400 kpa ±34 kPa (58 psi ±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 (Fig. 1). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement Fuel Pressure Regulator: Service and Repair Fuel Filter/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. 2 Looking Spring Tab 4. Depress locking spring tab on side of Fuel/Regulator (Fig. 2) 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. 3 Spring Tab In Locating Slot Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement > Page 2443 2. While applying downward pressure, rotate the Filter/Regulator clockwise until the the spring tab engages the locating slot (Fig. 3). 3. Connect the fuel line to the Filter/Regulator. 4. Lower vehicle from hoist. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement > Page 2444 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Filter/Fuel Pressure Regulator Replacement > Page 2445 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure > Page 2451 Fuel Pressure: Specifications Fuel System Volume Fuel System Volume Volume 1/4 Liter (1/2 pint) in 7 seconds Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2452 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2453 Tests 3 - 5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2454 Tests 6 - 10 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 pump capacity (volume) out of specs - Fuel pump relay fused B+ circuit - Fuel pump relay output circuit open Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2455 - Fuel pump ground circuit open/high resistance - Fuel pump module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center The fuel pump relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2459 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2460 Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2461 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 also protects the power circuit for the Automatic Shutdown (ASD) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL 1. Remove fuel pump module. Fig. 22 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 22). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Bolts ..................................................................................................................................... ..........................22.5 Nm (16.6 ft. lbs.) (200 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2468 Fuel Rail: Locations Fig. 15 Fuel Rail The fuel rail is mounted to the intake manifold (Fig. 15). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 2469 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 for information. The fuel rail is not repairable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair REMOVAL 1. Loosen fuel filler tube cap. Fig. 20 Fuel Filter Neck 2. Remove fuel filler neck screws (Fig. 20). 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. 21 Remove Filter Neck 8. Remove filler neck (Fig. 21). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 2474 7. Install fuel filler tube cap. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2478 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2479 Fuel Gauge Sender: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2480 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications IAC Motor-To-Throttle Body Bolts ....................................................................................................... ...................................................4.5 Nm (40 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2484 Idle Air Control (IAC) Motor: Locations Fig. 14 Idle Air Control Motor - Typical The Idle Air Control (IAC) motor is mounted on the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2485 Idle Air Control Motor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2486 Idle Air Control (IAC) Motor: Description and Operation Fig. 14 Idle Air Control Motor - Typical The Idle Air Control (IAC) motor is mounted on the throttle body. The PCM operates the idle air control motor. It is an electric stepper motor. The PCM adjusts engine idle speed through the idle air control motor 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 motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor 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). 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2487 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. 15 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 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2491 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2492 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2493 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2494 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2495 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2496 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center The fuel pump relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2501 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2502 Power Distribution Center Fuel Pump Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2503 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 also protects the power circuit for the Automatic Shutdown (ASD) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Auto Shut Down (ASD) Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2507 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2508 Fig.1 Power Distribution Center The ASD relay is located in the PDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2509 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2510 Power Distribution Center Automatic Shut Down Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2511 Auto Shut Down (ASD) Relay: Description and Operation Fig.1 Power Distribution Center The ASD relay is located in the PDC. The inside top of the PDC cover has label showing relay and fuse identification. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in ON or Start, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2512 Auto Shut Down (ASD) Relay: Service and Repair Fig.2 Power Distribution Center (PDC) REMOVAL The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 2516 Manifold Tuning Valve Relay: Diagrams Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 2517 Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations Rollover Valve: Locations All vehicles have rollover valve(s) on top of the fuel tank. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2521 Rollover Valve: Description and Operation All vehicles have rollover valve(s) on top of the fuel tank. The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. The rollover valves on the fuel tank are not serviceable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2526 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2527 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2528 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2529 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications IAC Motor-To-Throttle Body Bolts ....................................................................................................... ...................................................4.5 Nm (40 in. lbs) Throttle Body Mounting Bolts ..........................................................................................................................................23 Nm (16.9 ft. lbs.) (200 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2533 Throttle Body: Service and Repair REMOVAL Fig. 30 Battery Negative Cable 1. Disconnect the negative battery cable (Fig. 30). 2. Remove the air cleaner box cover. Fig. 31 Air Cleaner Element 3. Remove the air cleaner element (Fig. 31). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2534 Fig. 32 Throttle Body Bolts 6. Remove the bolts holding the throttle body to the air cleaner box (Fig. 32). Fig. 33 Disconnecting Throttle Cable Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2535 Fig. 34 Transmission Kickdown Cable Connector 7. Remove cable's from throttle body cam (Fig. 33) and (Fig. 34). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Fig. 35 Throttle Body Cable Attachment To Throttle Body Fig. 36 Disconnecting Throttle Cable 2. Working from the engine compartment, remove throttle cable from throttle body cam (Fig. 35) and (Fig. 36). 3. Lift the retaining tabs on the cable and slide cable out of bracket. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 2539 Fig. 2 Accelerator Pedal And Throttle Cable 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). Fig. 37 Retainer Clip 5. Remove retainer clip from throttle cable and grommet at the dashpanel (Fig. 37). 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. 36). 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. 37). 7. Install cable retainer clip (Fig. 37). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws .................................................................................................................................................2 Nm (17 in. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2543 Throttle Position Sensor: Locations Fig. 38 Throttle Position Sensor And Idle The throttle position sensor mounts to the side of the throttle body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2544 Throttle Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2545 Throttle Position Sensor: Description and Operation Fig. 38 Throttle Position Sensor And Idle 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2546 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 2551 Manifold Tuning Valve Relay: Diagrams Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve Relay <--> [Variable Induction Control Relay] > Component Information > Locations > Page 2552 Power Distribution Center Manifold Tuning Valve Relay (RT Package) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve Solenoid <--> [Variable Induction Control Solenoid] > Component Information > Diagrams Manifold Tuning Valve Solenoid (RT) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve <--> [Variable Induction Control Valve] > Component Information > Description and Operation Manifold Tuning Valve: Description and Operation MANIFOLD TUNING VALVE Fig. 17 Manifold Tuning Valve The valve connects both passages of the intake manifold plenum (Fig. 17). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve <--> [Variable Induction Control Valve] > Component Information > Description and Operation > Page 2559 Manifold Tuning 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. 18 Power Steering Bracket 4. Remove the bracket (Fig. 18). Fig. 19 Manifold Tuning Valve (MTV) 5. Remove the 2 bolts from the MTV (Fig. 19). NOTE: When removing the MTV do not loose the spring that is between the valve and intake manifold. 6. Remove the MTV. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Manifold Tuning Valve <--> [Variable Induction Control Valve] > Component Information > Description and Operation > Page 2560 Fig. 20 Electrical Connector 7. Disconnect the electrical from the MTV and bracket (Fig. 20). INSTALLATION 1. Connect the electrical connector to the MTV and bracket (Fig. 20). 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. 19). 4. Install the bracket (Fig. 18). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Electronic Ignition Coil Pack Ignition Coll Pack Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2566 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2567 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... .................................................................... 1-3-4-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2575 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2576 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2577 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2578 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2579 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2583 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2584 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2585 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2586 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2587 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications CABLE.................................................................................................................................................. ............................................................RESISTANCE #1 #4..................................................................................................................................................... ............................................. 3500 ohms - 4900 ohms #2 #3..................................................................................................................................................... ............................................. 2950 ohms - 4100 ohms Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Resistance Coil Polarity (Weastec) Coil Polarity (Diamond) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 2595 Ignition Coil: Mechanical Specifications Ignition Coil Mounting Bolts ..................................................................................................................................................11 Nm (8.1 ft. lbs) (95 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2596 Ignition Coil: Locations Fig.8 Ignition Coil Pack Ignition Coll Pack The coil pack consists of 2 coils molded together. The coil pack is mounted on the valve cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2597 Ignition Coil Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2598 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2599 Ignition Coil: Description and Operation Fig.8 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2600 Ignition Coil: Service and Repair REMOVAL Fig.10 Electronic Ignition Coil Pack The electronic ignition coil pack attaches directly to the valve cover. Fig.9 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 2604 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 2605 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 2606 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 2607 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Screw......................................................................................................... ..........................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2612 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2613 Camshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2614 Camshaft Position Sensor: Description and Operation Fig.3 Camshaft The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. The PCM sends approximately 8 volts to the hall affect 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. Fig.4 Target Magnet - Typical Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2615 Fig.5 Target Magnet Polarity A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern . As the target magnet rotates, the camshaft position sensor senses the change in polarity. The sensor output switch switches from high (5.0 volts) to low (0.5 volts) as the target magnet rotates. when the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The sensor also acts as a thrust plate to control camshaft endplay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2616 Camshaft Position Sensor: Service and Repair REMOVAL Fig.6 Camshaft Position Sensor Location The camshaft position sensor is mounted to the rear of the cylinder head. 1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition. 2. Disconnect electrical connectors from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.7 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft. INSTALLATION The camshaft position sensor is mounted to the rear of the cylinder head. The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft. 1. Install target magnet in end of camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in. lbs.) torque. 3. Place brake booster hose and electrical harness in holders on end of valve cover. 4. Attach electrical connectors to camshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Mounting Bolt ..................................................................................................................................................9 Nm (80 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2620 Crankshaft Position Sensor: Locations Fig. 4 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2621 Crankshaft Position Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2622 Crankshaft Position Sensor: Description and Operation Fig. 4 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). Fig. 5 Timing Reference Notches The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The second crankshaft counterweight has two sets of four timing reference notches including a 60 degree signature notch. The PCM sends approximately 8 volts to the Hall-effect 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. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2623 If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2624 Crankshaft Position Sensor: Service and Repair Fig. 6 Crankshaft Position Sensor REMOVAL The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. INSTALLATION The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Install sensor. Install sensor mounting screw and tighten. 2. Connect electrical connector to crankshaft position sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor....................................................................................................................................... .......................................................10 Nm (90 in. lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2633 Knock Sensor: Locations Fig.11 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2634 Knock Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2635 Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2636 Knock Sensor: Service and Repair Fig.11 Knock Sensor REMOVAL The knock sensor threads into the side of the cylinder block in front of the starter. 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION The knock sensor threads into the side of the cylinder block in front of the starter. 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft.lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube > Component Information > Service and Repair Spark Plug Tube: Service and Repair 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(R) parts cleaner or equivalent. 2. Apply Mopar(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube Seal - Valve Cover > Component Information > Description and Operation > Page 2644 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2651 Brake Transmission Shift Interlock Solenoid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2655 Throttle Converter Clutch Solenoid (ATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams Transmission Control Module: Diagrams Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 2661 Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Diagrams Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2670 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2671 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2672 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2676 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2677 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2678 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2679 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Diagrams Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-01A > Dec > 01 > Engine - Roughness With A/C ON, Below Normal Idle Speed PROM - Programmable Read Only Memory: Customer Interest Engine - Roughness With A/C ON, Below Normal Idle Speed NUMBER: 18-017-01 REV A GROUP: Vehicle Performance DATE: Dec. 7, 2001 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL DECEMBER 24, 2001. THE MDS2 MUST BE OPERATING WITH CIS CD2098 OR HIGHER. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-017-01, DATED JULY 20, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** WHICH INCLUDE CHANGES TO THE SYMPTOMS AND REVISED SOFTWARE. SUBJECT: Engine Idle Undershoot/Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2000 - 2001 (PL) Neon SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following symptoms: In ambient conditions typically below 16° C. (60° F) the engine may undershoot the normal idle speed when braking the vehicle to a stop (clutch depressed on manual transmission equipped vehicles).** ^ Engine roughness immediately after manually switching the A/C system "Off". Normal operation returns after a wide open throttle (WOT) occurrence or after engine restart. ^ **In ambient conditions between 10° and 20° C. (50° and 70° F) the engine may undershoot the normal idle speed at cold start gear engagement (2000 M.Y. with automatic transmission).** NOTE: **THE SOFTWARE PROVIDED WITH THIS BULLETIN ALSO INCLUDES THE SOFTWARE PROVIDED WITH TECHNICAL SERVICE BULLETIN 18-019-00 DATED OCTOBER 6, 2000.** DIAGNOSIS PROCEDURES: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-01A > Dec > 01 > Engine - Roughness With A/C ON, Below Normal Idle Speed > Page 2691 EQUIPMENT REQUIRED: REPAIR PROCEDURE: Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 1. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-01A > Dec > 01 > Engine - Roughness With A/C ON, Below Normal Idle Speed > Page 2692 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise PROM - Programmable Read Only Memory: Customer Interest A/C - Poor Performance/Expansion Valve Noise NUMBER: 24-008-01 GROUP: Heating & A/C DATE: Jun. 22, 2001 SUBJECT: Poor A/C Performance/Expansion Valve Noise OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) with new software and reducing the amount of R134A refrigerant in the system to 765 grams (27 oz. or 1.69 lbs.). MODELS: 2001 (PL) Neon 2001 (P2) Neon (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE JUNE 11, 2001 (MDH O611XX). SYMPTOM/CONDITION: Some vehicles may exhibit one or both of the following symptoms: ^ Under high ambient conditions, typically above 38°C. (100° F.), the A/C compressor may cycle off and on repeatedly producing poor A/C performance immediately after a hot engine restart or during city driving. ^ Under similar ambient conditions listed above the A/C expansion valve may be noisy (hum sound). DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2085 OR HIGHER. REPAIR PROCEDURE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 2697 1. Evacuate and recharge the A/C system to 765 grams (27 oz. or 1.69 lbs.) of R134A refrigerant as described on page 24-4 of the 2001 Neon Service Manual (Publication No. 81-270-1025). 2. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool). 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 cover the label with the clear plastic overlay. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 2698 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-00 > Oct > 00 > Engine - Tip In Hesitation PROM - Programmable Read Only Memory: Customer Interest Engine - Tip In Hesitation NUMBER: 18-020-00 GROUP: Vehicle Performance DATE: Oct. 6, 2000 SUBJECT: Tip In Hesitation Caused By High DI Fuel OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2001 (PL) Neon NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSAXLE BUILT PRIOR TO SEPT. 26, 2000 (MDH0926XX). SYMPTOM/CONDITION: Some vehicles may exhibit a cold start tip in hesitation when accelerating from a stop in ambient temperatures between 10° and 27°C (50° and 80°F). This condition will disappear in approximately 45 seconds after the start. See TSB 14-08-97 dated Nov. 21, 1997 for a detailed explanation of high DI fuel. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or is described by the customer, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING WITH CIS CD2069 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 System. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition to "ON". Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-00 > Oct > 00 > Engine - Tip In Hesitation > Page 2703 NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2 AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. 7. Type the necessary information on the "authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-00 > Oct > 00 > Engine - Tip In Hesitation > Page 2704 TIME ALLOWANCE: No: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-16-00 > Sep > 00 > Engine or A/C System - Poor Performance PROM - Programmable Read Only Memory: Customer Interest Engine or A/C System - Poor Performance NUMBER: 18-16-00 GROUP: Vehicle Performance DATE: Sept.15, 2000 SUBJECT: Poor A/C Or Engine Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2001 (PL) Neon NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 28, 2000 (MDHO828XX). SYMPTOM/CONDITION: Some vehicles may exhibit one or more symptom/conditions as follows: Poor A/C Performance In High Ambient Temperatures During high under hood temperatures with the engine coolant temperature less than 100°C (212°F), the A/C compressor may repeatedly disengage due to high head pressure. Disengagement of the A/C compressor may continue until speeds of 40 Kph (25 Mph) or more are reached. Poor Engine Performance In City Traffic During High Ambient Temperatures During high temperatures (greater than 35°C [95°F]) in stop and go traffic (at least 30 minutes). Some vehicle may exhibit poor acceleration (0 to 40 Kph [0 to 25 Mph] in 20 seconds) or experience difficulty exceeding 96 Kph (60 Mph). Cooling the engine corrects the condition. Engine Speed Undershoot Due To High DI Fuel In ambient conditions between 15°C and 26°C (60°F and 80°F) with the HVAC system set to A/C or defrost on an initial cold start. Some vehicles may exhibit an idle speed drop to approximately 400 rpm on the first A/C compressor engagement. Later A/C engagements are without occurrence. See TSB 14-08-97 dated Nov. 21, 1997 for a detailed explanation of High DI fuel. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III 7) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or is described by the customer, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2067 OR HIGHER. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-16-00 > Sep > 00 > Engine or A/C System - Poor Performance > Page 2709 REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2 AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-16-00 > Sep > 00 > Engine or A/C System - Poor Performance > Page 2710 FAILURE CODE: FM - Flash Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2716 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2717 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2718 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2719 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2720 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2721 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2722 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2723 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2724 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2725 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2726 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2727 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2728 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2729 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2730 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2731 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2732 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2733 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2734 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-017-01A > Dec > 01 > Engine - Roughness With A/C ON, Below Normal Idle Speed PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Roughness With A/C ON, Below Normal Idle Speed NUMBER: 18-017-01 REV A GROUP: Vehicle Performance DATE: Dec. 7, 2001 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL DECEMBER 24, 2001. THE MDS2 MUST BE OPERATING WITH CIS CD2098 OR HIGHER. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-017-01, DATED JULY 20, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** WHICH INCLUDE CHANGES TO THE SYMPTOMS AND REVISED SOFTWARE. SUBJECT: Engine Idle Undershoot/Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2000 - 2001 (PL) Neon SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following symptoms: In ambient conditions typically below 16° C. (60° F) the engine may undershoot the normal idle speed when braking the vehicle to a stop (clutch depressed on manual transmission equipped vehicles).** ^ Engine roughness immediately after manually switching the A/C system "Off". Normal operation returns after a wide open throttle (WOT) occurrence or after engine restart. ^ **In ambient conditions between 10° and 20° C. (50° and 70° F) the engine may undershoot the normal idle speed at cold start gear engagement (2000 M.Y. with automatic transmission).** NOTE: **THE SOFTWARE PROVIDED WITH THIS BULLETIN ALSO INCLUDES THE SOFTWARE PROVIDED WITH TECHNICAL SERVICE BULLETIN 18-019-00 DATED OCTOBER 6, 2000.** DIAGNOSIS PROCEDURES: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-017-01A > Dec > 01 > Engine - Roughness With A/C ON, Below Normal Idle Speed > Page 2739 EQUIPMENT REQUIRED: REPAIR PROCEDURE: Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 1. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-017-01A > Dec > 01 > Engine - Roughness With A/C ON, Below Normal Idle Speed > Page 2740 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins A/C - Poor Performance/Expansion Valve Noise NUMBER: 24-008-01 GROUP: Heating & A/C DATE: Jun. 22, 2001 SUBJECT: Poor A/C Performance/Expansion Valve Noise OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) with new software and reducing the amount of R134A refrigerant in the system to 765 grams (27 oz. or 1.69 lbs.). MODELS: 2001 (PL) Neon 2001 (P2) Neon (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE JUNE 11, 2001 (MDH O611XX). SYMPTOM/CONDITION: Some vehicles may exhibit one or both of the following symptoms: ^ Under high ambient conditions, typically above 38°C. (100° F.), the A/C compressor may cycle off and on repeatedly producing poor A/C performance immediately after a hot engine restart or during city driving. ^ Under similar ambient conditions listed above the A/C expansion valve may be noisy (hum sound). DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2085 OR HIGHER. REPAIR PROCEDURE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 2745 1. Evacuate and recharge the A/C system to 765 grams (27 oz. or 1.69 lbs.) of R134A refrigerant as described on page 24-4 of the 2001 Neon Service Manual (Publication No. 81-270-1025). 2. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool). 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 cover the label with the clear plastic overlay. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 2746 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-020-00 > Oct > 00 > Engine - Tip In Hesitation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Tip In Hesitation NUMBER: 18-020-00 GROUP: Vehicle Performance DATE: Oct. 6, 2000 SUBJECT: Tip In Hesitation Caused By High DI Fuel OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2001 (PL) Neon NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSAXLE BUILT PRIOR TO SEPT. 26, 2000 (MDH0926XX). SYMPTOM/CONDITION: Some vehicles may exhibit a cold start tip in hesitation when accelerating from a stop in ambient temperatures between 10° and 27°C (50° and 80°F). This condition will disappear in approximately 45 seconds after the start. See TSB 14-08-97 dated Nov. 21, 1997 for a detailed explanation of high DI fuel. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or is described by the customer, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING WITH CIS CD2069 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 System. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition to "ON". Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-020-00 > Oct > 00 > Engine - Tip In Hesitation > Page 2751 NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2 AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. 7. Type the necessary information on the "authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-020-00 > Oct > 00 > Engine - Tip In Hesitation > Page 2752 TIME ALLOWANCE: No: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-16-00 > Sep > 00 > Engine or A/C System - Poor Performance PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine or A/C System - Poor Performance NUMBER: 18-16-00 GROUP: Vehicle Performance DATE: Sept.15, 2000 SUBJECT: Poor A/C Or Engine Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2001 (PL) Neon NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 28, 2000 (MDHO828XX). SYMPTOM/CONDITION: Some vehicles may exhibit one or more symptom/conditions as follows: Poor A/C Performance In High Ambient Temperatures During high under hood temperatures with the engine coolant temperature less than 100°C (212°F), the A/C compressor may repeatedly disengage due to high head pressure. Disengagement of the A/C compressor may continue until speeds of 40 Kph (25 Mph) or more are reached. Poor Engine Performance In City Traffic During High Ambient Temperatures During high temperatures (greater than 35°C [95°F]) in stop and go traffic (at least 30 minutes). Some vehicle may exhibit poor acceleration (0 to 40 Kph [0 to 25 Mph] in 20 seconds) or experience difficulty exceeding 96 Kph (60 Mph). Cooling the engine corrects the condition. Engine Speed Undershoot Due To High DI Fuel In ambient conditions between 15°C and 26°C (60°F and 80°F) with the HVAC system set to A/C or defrost on an initial cold start. Some vehicles may exhibit an idle speed drop to approximately 400 rpm on the first A/C compressor engagement. Later A/C engagements are without occurrence. See TSB 14-08-97 dated Nov. 21, 1997 for a detailed explanation of High DI fuel. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III 7) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or is described by the customer, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2067 OR HIGHER. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-16-00 > Sep > 00 > Engine or A/C System - Poor Performance > Page 2757 REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2 AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: > 18-16-00 > Sep > 00 > Engine or A/C System - Poor Performance > Page 2758 FAILURE CODE: FM - Flash Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2764 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2765 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2766 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2767 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2768 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2769 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2770 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2771 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2772 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2773 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2774 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2775 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2776 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2777 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2778 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2779 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2780 ^ 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2781 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2782 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 2789 Brake Transmission Shift Interlock Solenoid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2793 Throttle Converter Clutch Solenoid (ATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 2799 Brake Transmission Shift Interlock Solenoid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2803 Throttle Converter Clutch Solenoid (ATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation Accumulator: Description and Operation DESCRIPTION The accumulator (Fig. 97) is a hydraulic device that has the sole purpose of cushioning the application of a band or clutch. The accumulator consists of a dual-land piston and a spring located in a bore in the transmission case. OPERATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Page 2807 Line pressure is directed between the lands of the piston (Fig. 98), bottoming it against the accumulator plate. The accumulator stays in this position after the transmission is placed into a Drive position. When the 1-2 upshift occurs (Fig. 99), line pressure is directed to the large end of the piston and then to the kickdown servo. As the line pressure reaches the accumulator, the combination of spring pressure and line pressure forces the piston away from the accumulator plate. This causes a balanced pressure situation, which results in a cushioned band application. After the kickdown servo has become immovable, line pressure will finish pushing the accumulator up into its bore. When the large end of the accumulator piston is seated in its bore, the band or clutch is fully applied. NOTE: The accumulator is shown in the inverted position for illustrative purposes. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications Kickdown (Front) 2 1/4 turns - Backed Off From 8 Nm (72 inch lbs.) Low-Reverse (Rear) 3 1/2 turns - Backed Off From 5 Nm (41 inch lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 2811 Band: Description and Operation BANDS KICKDOWN (FRONT) BAND DESCRIPTION The kickdown, or "front", band (Fig. 100) holds the common sun gear of the planetary gear sets. The front (kickdown) band is made of steel, and faced on its inner circumference with a friction-type lining. One end of the band is anchored to the transmission case, and the other is acted on with a pushing force by a servo piston. The front band is a single-wrap design (the band does not completely encompass/ wrap the drum that it holds). OPERATION The kickdown band holds the common sun gear of the planetary gear sets by applying and holding the front clutch retainer, which is splined to the sun gear driving shell, and in turn splined directly to the sun gear. The application of the band by the servo is typically done by an apply lever and link bar. LOW/REVERSE (REAR) BAND DESCRIPTION The low/reverse band, or "rear", band (Fig. 101) is similar in appearance and operation to the front band. The rear band is also a single-wrap design (the band does not completely encompass/wrap the drum that it holds). OPERATION The rear band holds the rear planet carrier stationary by being mounted around and applied to the low/reverse drum. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 2812 Band: Adjustments ADJUSTMENT - FRONT BAND The front (kickdown) band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Loosen band adjusting screw locknut (Fig. 102). Then back locknut off 3-5 turns. Be sure adjusting screw turns freely in case. Apply lubricant to screw threads if necessary. 4. Tighten band adjusting screw to 8 Nm (72 inch lbs.). 5. Back off front band adjusting screw 2 1/4 turns. 6. Hold adjuster screw in position and tighten locknut to 47 Nm (35 ft. lbs.) torque. 7. Install air cleaner assembly. 8. Connect battery negative cable. ADJUSTMENTS - REAR BAND The transmission oil pan must be removed for access to the rear (low/reverse) band adjusting screw. 1. Raise vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 2813 2. Remove transaxle oil pan and drain fluid (Fig. 103) (Fig. 104). 3. Loosen band adjusting screw locknut 5-6 turns. Be sure adjusting screw turns freely in lever. 4. Tighten adjusting screw to 5 Nm (41 inch lbs.) (Fig. 105). 5. Back off adjusting screw 3 1/2 turns. 6. Hold adjusting screw in place and tighten locknut to 14 Nm (125 ft. lbs.) torque. 7. Install a bead of Mopar(R) Silicone Rubber Adhesive Sealant to the oil pan and install to case immediately. 8. Install oil pan-to-case bolts and torque to 19 Nm (165 inch lbs.). 9. Lower vehicle and refill transmission with Mopar(R) ATF Plus 4, Type 9602, fluid. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Description and Operation > Kickdown Band Apply Servo: Description and Operation Kickdown SERVO - KICKDOWN DESCRIPTION The kickdown servo (Fig. 189) consists of a two-land piston with an inner piston, a piston rod and guide, and a return spring. The dual-land piston uses seal rings on its outer diameters and an O-ring for the inner piston. OPERATION The application of the piston is accomplished by applying pressure between the two lands of the piston. The pressure acts against the larger lower land to push the piston downward, allowing the piston rod to extend though its guide against the apply lever. Release of the servo at the 2-3 upshift is accomplished by a combination of spring and line pressure, acting on the bottom of the larger land of the piston. The small piston is used to cushion the application of the band by bleeding oil through a small orifice in the larger piston. The release timing of the kickdown servo is very important to obtain a smooth but firm shift. The release has to be very quick, just as the front clutch application is taking place. Otherwise, engine runaway or a shift hesitation will occur. To accomplish this, the band retains its holding capacity until the front clutch is applied, giving a small amount of overlap between them. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Description and Operation > Kickdown > Page 2818 Band Apply Servo: Description and Operation Low/Reverse SERVO - LOW/REVERSE DESCRIPTION The rear (low/reverse) servo consists of a single stage or diameter piston and a spring loaded plug. The spring is used to cushion the application of the rear (low/reverse) band. OPERATION While in the de-energized state (no pressure applied), the piston is held up in its bore by the piston spring. The plug is held down in its bore, in the piston, by the plug spring. When pressure is applied to the top of the piston, the plug is forced down in its bore, taking up any clearance. As the piston moves, it causes the plug spring to compress, and the piston moves down over the plug. The piston continues to move down until it hits the shoulder of the plug and fully applies the band. The period of time from the initial application, until the piston is against the shoulder of the plug, represents a reduced shocking of the band that cushions the shift. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown Band Apply Servo: Service and Repair Kickdown Disassembly SERVO - KICKDOWN DISASSEMBLY 1. Remove kickdown servo snap ring (Fig. 190). 2. Remove kickdown servo rod guide and snap ring (Fig. 191). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown > Page 2821 3. Remove kickdown piston return spring and piston (Fig. 192). 4. Disassemble piston assembly as shown in (Fig. 193). Cleaning and Inspection SERVO - KICKDOWN CLEANING Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown > Page 2822 Clean the servo piston components (Fig. 194) with solvent and dry them with compressed air. Wipe the band clean with lint free shop towels. Replace the front band if distorted, lining is burned, flaking off, or worn to the point where the grooves in the lining material are no longer visible. Replace any servo component if doubt exists about condition. Do not reuse suspect parts. INSPECTION Inspect the servo components (Fig. 195). Replace the springs if collapsed, distorted or broken. Replace the guide, rod and piston if cracked, bent, or worn. Discard the servo snap-ring if distorted or warped. Check the servo piston bore for wear. If the bore is severely scored, or damaged, it will be necessary to replace the case. Assembly SERVO - KICKDOWN ASSEMBLY 1. Lubricate new O-ring and seal rings with petroleum jelly and install them on piston, guide and rod. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown > Page 2823 2. Install rod in piston. Install spring and washer on rod. Compress spring and install snap-ring (Fig. 196). 3. Install piston and return spring (Fig. 192). 4. Install rod guide and snap ring (Fig. 191) (Fig. 190). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown > Page 2824 Band Apply Servo: Service and Repair Low/Reverse Disassembly SERVO - LOW/REVERSE DISASSEMBLY 1. Back off low/reverse band adjustment and position lever out of the way (Fig. 197). 2. Remove low/reverse servo snap ring (Fig. 198). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown > Page 2825 3. Remove retainer, spring and servo (Fig. 199). Cleaning SERVO - LOW/REVERSE CLEANING Remove and discard the servo piston seal ring (Fig. 200). Then clean the servo components with solvent and dry with compressed air. Replace either spring if collapsed, distorted or broken. Replace the plug and piston if cracked, bent, or worn. Discard the servo snap-rings and use new ones at assembly. Assembly SERVO - LOW/REVERSE ASSEMBLY Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Kickdown > Page 2826 1. Install low/reverse servo assembly (Fig. 201). 2. Install low/reverse servo snap ring (Fig. 198). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Bell Housing, A/T > Component Information > Specifications Bell Housing: Specifications Bolt, Starter Motor-To-Transaxle 40 ft.lb Bolt, Transaxle Case-to-Engine Block 70 ft.lb Bolt, Transfer Gear Cover-To-Case 165 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Front Clutch (Not Adjustable) 0.050 - 0.110 in Rear Clutch 0.028 - 0.043 in Front Clutch Retainer end play 0.030 - 0.106 inch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Front Clutch Clutch: Description and Operation Front Clutch DESCRIPTION The front clutch assembly (Fig. 113) is composed of the front clutch retainer, pressure plate, clutch plates, driving discs, piston, piston return spring, return spring retainer, and snap-rings. The front clutch is the forward-most component in the transmission geartrain and is directly behind the oil pump. It is considered a driving component. NOTE: The number of discs and plates may vary with each engine and vehicle combination. OPERATION The apply the clutch, pressure is applied between the clutch retainer and piston. The fluid pressure is provided by the oil pump, transferred through the control valves and passageways, and enters the clutch through the hub of the reaction shaft support. With pressure applied between the clutch retainer and piston, the piston moves away from the clutch retainer and compresses the clutch pack. This action applies the clutch pack, allowing torque to flow through the input shaft into the driving discs, and into the clutch plates and pressure plate that are lugged to the clutch retainer. The waved snap-ring is used to cushion the application of the clutch pack. In some transmissions, the snap-ring is selective and used to adjust clutch pack clearance. When pressure is released from the piston, the spring returns the piston to its fully released position and disengages the clutch. The release spring also helps to cushion the application of the clutch assembly. When the clutch is in the process of being released by the release spring, fluid flows through a Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Front Clutch > Page 2835 vent and one-way ball-check-valve located in the clutch retainer. The check-valve is needed to eliminate the possibility of plate drag caused by centrifugal force acting on the residual fluid trapped in the clutch piston retainer. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Front Clutch > Page 2836 Clutch: Description and Operation Rear Clutch DESCRIPTION The rear clutch assembly (Fig. 126) is composed of the input shaft, rear clutch retainer, pressure plate, clutch plates, driving discs, piston, Belleville spring, and snap-rings. The Belleville spring acts as a lever to multiply the force applied on to it by the apply piston. The increased apply force on the rear clutch pack, in comparison to the front clutch pack, is needed to hold against the greater torque load imposed onto the rear pack. The rear clutch is directly behind the front clutch and is considered a driving component. NOTE: The number of discs and plates may vary with each engine and vehicle combination. OPERATION To apply the clutch, pressure is applied between the clutch retainer and piston. The fluid pressure is provided by the oil pump, transferred through the control valves and passageways, and enters the clutch through the hub of the reaction shaft support. With pressure applied between the clutch retainer and piston, the piston moves away from the clutch retainer and compresses the clutch pack. This action applies the clutch pack, allowing torque to flow through the input shaft into the driving discs, and into the clutch plates and pressure plate that are lugged to the clutch retainer. The waved snap-ring is used to cushion the application of the clutch pack. In some transmissions, the snap-ring is selective and used to adjust clutch pack Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Front Clutch > Page 2837 clearance. When pressure is released from the piston, the spring returns the piston to its fully released position and disengages the clutch. The release spring also helps to cushion the application of the clutch assembly. When the clutch is in the process of being released by the release spring, fluid flows through a vent and one-way ball-check-valve located in the clutch retainer. The check-valve is needed to eliminate the possibility of plate drag caused by centrifugal force acting on the residual fluid trapped in the clutch piston retainer. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch Clutch: Service and Repair Front Clutch DISASSEMBLY 1. Remove front clutch waved snap ring using a suitable screwdriver (Fig. 108). 2. Remove waved snap ring and reaction plate (Fig. 109). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2840 3. Remove clutch pack (Fig. 110). 4. Using tool C3575A, compress front clutch return spring and remove snap ring (Fig. 111). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2841 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2842 5. Remove retainer, return spring and piston (Fig. 112) (Fig. 113). ASSEMBLY Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2843 1. Install front clutch piston, return spring, and retainer (Fig. 113) (Fig. 114). 2. Compress front clutch return spring using Tool C3575A and install snap ring (Fig. 115). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2844 3. Install front clutch pack (Fig. 116). 4. Install reaction plate and waved snap ring (Fig. 117) (Fig. 118). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2845 5. Using feeler gauge, measure front clutch clearance (Fig. 119). Front clutch clearance should be within 1.27 - 2.79 mm (0.050 - 0.110 inch) and is not adjustable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2846 Clutch: Service and Repair Rear Clutch DISASSEMBLY Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2847 1. Remove rear clutch snap ring (Fig. 120) (Fig. 126). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2848 2. Remove rear clutch pack (Fig. 121). 3. Remove piston/belleville snap ring (Fig. 122). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2849 4. Remove rear clutch piston and belleville spring (Fig. 123). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2850 5. Remove input shaft-to-clutch retainer snap ring (Fig. 124) (Fig. 125). Press input shaft out of retainer if necessary. ASSEMBLY Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2851 1. Install input shaft-to-clutch retainer snap ring (Fig. 127) (Fig. 128) (Fig. 126). 2. Install rear clutch piston, belleville spring and waved snap ring (Fig. 129). Install snap ring using a suitable screwdriver (Fig. 130). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2852 3. Install rear clutch pack (Fig. 131). 4. Install snap ring using a suitable screwdriver (Fig. 132). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 2853 5. Using feeler gauges, measure rear clutch clearance (Fig. 133). Rear clutch clearance should be within 0.71 - 1.10 mm (0.028 - 0.043 inch). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams Transmission Control Module: Diagrams Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 2857 Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments Differential Output Shaft: Adjustments ADJUSTMENT - OUTPUT SHAFT BEARING 1. With output shaft gear removed, install a 13.65 mm (0.537 inch) and a 1.34 min (0.053 inch) gauging shims on the planetary rear annulus gear hub using grease to hold the shims in place. The 13.65 mm shim has a larger inside diameter and must be installed over the output shaft first. The 1.34 mm shim pilots on the output shaft. 2. Install output shaft gear and bearing assembly, torque to 271 Nm (200 ft. lbs.). 3. To measure bearing end play: 4. Attach Tool L-4432 to the output shaft gear. 5. Mount a steel ball with grease into the end of the output shaft. 6. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers. 7. Using a dial indicator, mounted to the transaxle case, measure output shaft end play. 8. Once bearing end play has been determined, refer to the output shaft bearing shim chart. 9. The 12.65 mm (0.498 inch), 13.15 mm (0.518 inch) or 13.65 mm (0.537 inch) shims are always installed first. These shims have lubrication slots which are necessary for proper bearing lubrication. 10. Shims thinner than 12.65 mm listed in the chart are common to both the transfer shaft and output shaft bearings. 11. Use Tool L-4434 to remove the retaining nut and washer. To remove the output shaft gear use Tool L-4407. 12. Remove the two gauging shims and install the proper shim combination, making sure to install the 12.65, 13.15, or 13.65 mm shim first. Use grease to hold the shims in place. Install the output shaft gear and bearing assembly. 13. Install the retaining nut and washer and torque to 271 Nm (200 ft. lbs.). 14. Using an inch-pound torque wrench, check the turning torque. The torque should be between 3 and 8 inch-pounds. 15. If the turning torque is too high, install a 0.05 mm (0.002 inch) thicker shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds. OUTPUT SHAFT BEARING SHIM CHART Part 1 of 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2862 OUTPUT SHAFT BEARING SHIM CHART Part 2 of 2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2863 Differential Output Shaft: Service and Repair TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING REMOVAL NOTE: Transfer Gear should be removed for repair of output shaft, to obtain an accurate output shaft turning torque measurement upon reassembly. NOTE: Transaxle geartrain must be removed to gain access to and service output shaft. 1. Using a suitable punch, bend retaining strap tabs flat to facilitate bolt removal (Fig. 236). 2. Remove retaining strap and stirrup-to-gear bolts (Fig. 237). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2864 3. Remove retaining strap (Fig. 238). 4. Remove stirrup (Fig. 239). 5. Using Tool L-4434, remove output shaft retaining nut and washer (Fig. 240). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2865 6. Using Tool L-4407 as shown in (Fig. 241), remove output shaft gear and select shim (Fig. 242). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2866 7. Remove output shaft/rear annulus gear assembly (Fig. 243). 8. Remove output shaft gear bearing cone using Tool L-4406-1 and adapters L-4406-2 (Fig. 244). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2867 9. Using an arbor press, remove output shaft from rear annulus gear (Fig. 245). 10. Using Tool L-4406-1 and adapters L-4406-2, remove rear planetary annulus gear bearing cone (Fig. 246). 11. Using Tool L-4518, remove output shaft gear bearing cup from rear of transaxle case (Fig. 247). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2868 12. Using Tool L-4518, remove output shaft gear bearing cup from inside transaxle case (Fig. 248). INSTALLATION 1. Install output shaft bearing cone using Tool L-4408, C-4171, and a suitable press (Fig. 249). 2. Install rear planetary annulus gear bearing -one using tool C-4637 and cup from Tool L-4518 (Fig. 250). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2869 3. Using a press and a 1/2" socket to protect the shaft, install output shaft into rear planetary annulus gear (Fig. 251). 4. Using Tool L-4429-3, install both output shaft bearing cups to transaxle case (Fig. 252) (Fig. 253). 5. Determine output shaft bearing shim thickness. Shim thickness need be determined only if any of the following parts are replaced: - Transaxle case - Output shaft - Rear planetary annulus gear - Output shaft gear - Rear annulus and output shaft gear bearing cones Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2870 - Overrunning clutch race cups To determine proper shim thickness, Refer to Output Shaft Bearing Adjustment. Check output shaft bearing turning torque, using an inch-pound torque wrench. If turning torque is 3 - 8 inch lbs., the proper shim has been installed. 6. Install output shaft assembly with appropriate shim (Fig. 254) (Fig. 255). 7. Install output shaft gear onto shaft. Use Tool L-4439 to get gear started (Fig. 256). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2871 8. Install Tool L-4434 and C-4658. Install washer and nut (Fig. 257). 9. Torque output shaft retaining nut to 271 Nm (200 ft. lbs.) (Fig. 258). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2872 10. Set up Tool L-4432 and C-4658 as shown in (Fig. 259). Install dial indicator and measure output shaft end play. 11. Using an inch lbs. torque wrench, measure output shaft bearing turning torque (Fig. 260). 12. Install stirrup and strap. Install bolts but do not tighten. NOTE: Once the stirrup assembly is positioned onto the output gear, it is necessary to "clock" the stirrup against the flats of the output gear retaining nut. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Output Shaft, A/T > Component Information > Adjustments > Page 2873 13. Rotate stirrup clockwise against flats of gear retaining nut (Fig. 261). 14. Torque stirrup and strap bolts to 23 Nm (200 inch lbs.) (Fig. 262). 15. Bend tabs of strap up against "flats"of retaining bolts to prevent bolts from backing out of gear in the event they come loose. 16. Install transfer shaft and gear. 17. Assemble transaxle geartrain. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments Differential Transfer Shaft: Adjustments ADJUSTMENT - TRANSFER SHAFT BEARING 1. Use Tool L-4434 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L-4407. 2. Install a 2.29 mm (0.090 inch) and a 1.39 mm (0.055 inch) gauging shims on the transfer shaft behind the governor support. 3. Install transfer shaft gear and bearing assembly and torque the nut to 271 Nm (200 ft. lbs.). 4. To measure bearing end play:Attach Tool L-4432 to the transfer gear. 5. Mount a steel ball with grease into the end of the transfer shaft. 6. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers. 7. Using a dial indicator, measure transfer shaft en play. 8. Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting. 9. Use Tool L-4434 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L-4407. 10. Remove the two gauging shims and install the correct shim combination. Install the transfer gear and bearing assembly. 11. Install the retaining nut and washer and torque to 271 Nm (200 ft. lbs.). Measure transfer shaft end play, end play should be 0.05 to 0.25 mm (0.002 to 0.010 inch). 12. Measure bearing end play as outlined in Step (4). End play should be between 0.05 mm and 0.25 mm (0.002 to 0.010 inch). NOTE: If end play is too high, install a 0.05 mm (0.002 inch) thinner shim combination. If end play is too low, install a 0.05 mm (0.002 inch) thicker shim combination. Repeat until 0.05 to 0.25 mm (0.002 to 0.010 inch) end play is obtained. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2877 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2878 Differential Transfer Shaft: Service and Repair REMOVAL 1. Remove transfer gear cover bolts (Fig. 263). 2. Separate transfer gear cover from transaxle (Fig. 264). Repair any cover imperfections. Clean cover and case of old adhesive sealant. 3. Using a suitable punch, bend retaining strap tabs to facilitate bolt removal. 4. Remove stirrup and retaining strap-to-transfer gear bolts. 5. Remove stirrup and retaining strap. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2879 6. Using Tool L-4434 (Fig. 265), remove transfer shaft gear retaining nut and washer (Fig. 266). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2880 7. Using Tool L-4407A, remove transfer shaft gear and select shim (Fig. 267). 8. Using Tool L-4406-1 and adapter L-4406-3, remove transfer shaft gear bearing cone (Fig. 268). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2881 9. Remove governor support retainer (Fig. 269). 10. Remove governor support retainer bearing cup (Fig. 270). 11. If necessary, remove low/reverse band anchor pin (Fig. 271). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2882 12. Remove governor assembly (Fig. 272). 13. Remove transfer shaft bearing retainer snap ring (Fig. 273). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2883 14. Set up tools as shown in (Fig. 274). 15. Remove transfer shaft/bearing retainer assembly (Fig. 275). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2884 16. Separate bearing retainer from transfer shaft (Fig. 276). 17. Remove transfer shaft bearing cone from shaft using Tool C-293-PA and adapters C-293-52 (Fig. 277). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2885 18. Remove transfer shaft bearing cup from bearing retainer (Fig. 278). INSTALLATION 1. Install transfer shaft bearing cup to bearing retainer using Tool L-4520 (Fig. 279). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2886 2. Install transfer shaft bearing cone to transfer shaft using Tool L-4111 (Fig. 280). 3. Assemble transfer shaft to bearing retainer (Fig. 281). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2887 4. Install transfer shaft/bearing retainer assembly using tool L-4512 (Fig. 282). 5. Install transfer shaft bearing retainer snap ring (Fig. 283). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2888 6. Install governor assembly (Fig. 284). 7. Install low/reverse band anchor pin if previously removed (Fig. 285). 8. Install governor support retainer bearing cup using Tool L-4520 (Fig. 286). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2889 9. Install governor support retainer (Fig. 287). 10. Install transfer shaft gear bearing cone using Tool L-4410 (Fig. 288). 11. Determine transfer shaft bearing shim thickness. Shim thickness need be determined only if any of the following parts are replaced: Transaxle case - Transfer shaft - Transfer shaft gear - Transfer shaft bearings - Governor support retainer - Transfer shaft bearing retainer - Retainer snap ring - Governor support Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2890 12. Install transfer shaft gear and select shim (Fig. 289). 13. Install transfer shaft gear nut and washer (Fig. 290). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2891 14. Using Tool L-4434 and adapter C-4658 (Fig. 291), torque transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.). 15. Measure transfer shaft end play. Set up Tool L-4432 and C-4658 as shown in (Fig. 292). Measure end play with dial indicator. 16. Position stirrup and strap on transfer gear. 17. Install bolts but do not tighten. 18. Rotate stirrup clockwise until it contacts transfer gear retaining nut flat. 19. Torque stirrup and strap-to-transfer gear bolts to 23 Nm (200 inch lbs.). 20. Bend tabs of strap up against "flats" of retaining bolts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Adjustments > Page 2892 21. Install a bead of Mopar(R) Silicone Rubber Adhesive Sealant to transfer gear cover (Fig. 293). Immediately install to transaxle case. 22. Install and torque transfer gear cover-to-case bolts (Fig. 294) to 19 Nm (165 inch lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Bolt, Extension Housing-To-Case 250 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2900 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2901 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2902 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2903 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2904 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Estimated Service Fill .......................................................................................................................... ...................................................... 3.8Liters (4.0 Qt) Overhaul Fill with Empty Converter .......................................................................................................................................................... 8.1Liters (8.6 Qt) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2907 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ..................................... Mopar ATF + 4, Type 9602 NOTE: Dexron III / Mercon is not recommended. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 2908 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 2909 Fluid - A/T: Testing and Inspection FLUID LEVEL AND CONDITION CHECK NOTE: The transmission and differential sump have a common oil sump with a communicating opening between the two. FLUID LEVEL CHECK 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. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82°C or 180°F). The fluid level is correct if it is in the HOT region (crosshatched area) on the fluid level indicator (Fig. 159). 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, the air bubbles can cause overheating, fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and servo operation. Foaming can also result in fluid escaping from the transaxle dipstick where it may be mistaken for a leak. 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 overhaul is needed. 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. 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 needed. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check Procedure for Checking Fluid Level To properly check the automatic transaxle fluid level, 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 at 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 and determine if the fluid is hot or warm. Hot fluid is approximately 180°F (82°C) that is the normal operating temperature after the vehicle has been driven at least 15 miles. The fluid cannot be comfortable held between the finger tips. Warm is when fluid is between 85° to 125°F (29° to 52°C). 6. Wipe the dipstick clean and reinsert until seated. Remove dipstick and note reading. If the fluid is hot, reading should be in the cross hatched area marked "HOT" between the upper two holes in the dipstick. If the fluid is warm, the fluid level should be between the lower two holes, into the area marked "WARM". If the fluid level shows low, add sufficient transmission fluid to bring to the proper level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 2912 Fluid - A/T: Service and Repair Fluid and Filter Change STANDARD PROCEDURE - FLUID AND FILTER CHANGE NOTE: For the recommended maintenance (fluid/filter change) intervals for this transaxle, (Refer to MAINTENANCE) NOTE: Only fluids of the type labeled Mopar(R) 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. NOTE: 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. Remove oil filter-to-valve body screws (Fig. 160). 4. Remove oil filter and gasket (Fig. 161). 5. Install a new filter and gasket (Fig. 161). 6. Clean the oil pan and magnet. Reinstall pan using new Mopar(R) Silicone Rubber Adhesive Sealant. Torque oil pan bolts to 19 Nm (165 inch lbs.). 7. Pour four quarts of Mopar(R) ATF +4 (Automatic Transmission Fluid-Type 9602) through the dipstick opening. 8. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 2913 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick (Fig. 162). 10. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 11. 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 TM 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(R) 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 "ADD" mark on the dipstick (Fig. 162). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Screw, Fluid Filter 45 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 2917 Fluid Filter - A/T: Service and Repair STANDARD PROCEDURE - FLUID AND FILTER CHANGE NOTE: For the recommended maintenance (fluid/filter change) intervals for this transaxle, (Refer to MAINTENANCE) NOTE: Only fluids of the type labeled Mopar(R) 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. NOTE: 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. Remove oil filter-to-valve body screws (Fig. 160). 4. Remove oil filter and gasket (Fig. 161). 5. Install a new filter and gasket (Fig. 161). 6. Clean the oil pan and magnet. Reinstall pan using new Mopar(R) Silicone Rubber Adhesive Sealant. Torque oil pan bolts to 19 Nm (165 inch lbs.). 7. Pour four quarts of Mopar(R) ATF +4 (Automatic Transmission Fluid-Type 9602) through the dipstick opening. 8. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 2918 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the "ADD" mark on the dipstick (Fig. 162). 10. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 11. 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 TM 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(R) 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 "ADD" mark on the dipstick (Fig. 162). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Line Splice Kit Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Splice Kit NUMBER: 07-004-00 GROUP: Cooling DATE: Jan. 12, 2001 SUBJECT: Transaxle Cooler Line Splice Kit MODELS: DISCUSSION: A connector kit p/n 05016918AA has been released to make transaxle cooler line service easier. This kit should be installed whenever service is performed that requires cooler line removal from the transaxle. This will make the lines easy to remove and install should service be required at a later time. An instruction sheet is included with each kit that details installation procedures. PARTS REQUIRED: POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 2923 Fluid Line/Hose: Specifications Transmission Hose Clamps 18 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL 1. Loosen hose clamps. 2. Remove hoses from transaxle (Fig. 3) and cooler fittings (Fig. 4). INSTALLATION 1. Install hoses to transaxle (Fig. 3) and cooler fittings (Fig. 4). 2. Position hose clamps on fittings and tighten to 3 Nm (28 inch lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 2926 Fluid Line/Hose: Service and Repair Flushing Coolers and Tubes 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 AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. 1. Remove cover plate filler plug on Tool 6906. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Use Mopar(R) 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(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Bolt, Oil Pan-To-Case 165 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Outer Gear-To-Pocket 0.018 - 0.0056 in Outer Gear Side Clearance 0.0008 - 0.0018 in Inner Gear Side Clearance 0.0008 - 0.0018 in Lubrication Method Pump (internal-external gear-type) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 2933 Fluid Pump: Description and Operation DESCRIPTION The oil pump is located in the pump housing inside the bell housing of the transmission case. The oil pump consists of an inner and outer gear, a housing, and a cover that also serves as the reaction shaft support (Fig. 175). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 2934 Fluid Pump: Testing and Inspection OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. Refer to the Fluid Level Check procedure. If necessary, fill the transmission to the proper level with Mopar(R) ATF +4, type 9602, Automatic Transmission Fluid. 1. Using hose cutters or a suitable blade, cut the To cooler line off flush with the cooler inlet fitting and place a collecting 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. Run the engine at curb idle speed, with the shift selector in neutral. 3. If one quart of transmission fluid is collected in the container in 20 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 20 seconds to collect one quart of fluid. 4. Re-connect the To cooler line to the transmission cooler inlet using a service splice kit. Refer to instructions included with the kit. 5. Refill the transmission to proper level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 DISASSEMBLY 1. Remove reaction shaft support-to-pump body bolts. 2. Remove reaction shaft support, and the inner and outer pump gears (Fig. 176). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 2937 Fluid Pump: Service and Repair Cleaning and Inspection CLEANING Clean pump and support components with solvent and dry them with compressed air. INSPECTION 1. Check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn. 2. Visually inspect the pump and support components. Replace the pump assembly if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump assembly if the gears if pitted, worn chipped, or damaged. 3. Inspect the pump bushing. Then check the reaction shaft support bushing. Replace the pump assembly if either bushing is heavily worn, scored or damaged. 4. Clearance between outer gear and reaction shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 inch). Clearance between inner gear and reaction shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 inch). Both clearances can be measured at the same time by installing the gears in the pump body and measure pump component clearances as follows: 5. Reinstall gears to pump body and measure outer gear-to-pocket clearance with a feeler gauge (Fig. 177). Outer gear-to-pocket clearance should be within 0.045 - 0.141 mm (0.0018 - 0.0056 inch). 6. Measure both inner and outer gear side clearance with Plastigage(Tm). If Plastigage TM is not available, measure across the pump body with a straight edge and feeler gauge. a. Position an appropriate piece of Plastigage TM across both gears. b. Align the plastigage to a flat area on the reaction shaft housing. c. Install the reaction shaft support to the pump housing and torque to 28 Nm (250 inch lbs.). d. Separate the reaction shaft housing from the pump housing and measure the Plastigage(Tm) following the instructions supplied with it. Inner and outer gear side clearance should be within 0.020 - 0.046 mm (0.0008 - 0.0018 inch). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 2938 Fluid Pump: Service and Repair Assembly ASSEMBLY 1. Install inner and outer gears to pump body (Fig. 176). Lubricate gears with Mopar(R) ATF +4 (Automatic Transmission Fluid-Type 9602). 2. Install reaction shaft support to pump body and align holes. 3. Install and torque reaction shaft support-to-pump body bolts to 28 Nm (250 inch lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications Governor: Specifications Bolt, Governor-To-Support 60 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 2942 Governor: Description and Operation DESCRIPTION The governor assembly is fastened to the transaxle transfer shaft. It consists of a governor body, weight, valve, and shaft, OPERATION The governor meters hydraulic pressure, and this metered pressure is used to signal the transmission when it is time for a shift to occur. It does this by balancing governor pressure on one side of a shift valve, and throttle pressure on the other. When governor pressure increases far enough to overcome the throttle pressure on the valve, a shift occurs. With the gearshift selector in a forward driving range, line pressure flows from the manual valve and down to the governor valve. When the output shaft starts to rotate with vehicle motion, the governor weight assembly will start to move outward due to centrifugal force. As the weight is moved outward, it will pull the valve with it until the land of the valve uncovers the line pressure port. As the port begins to become uncovered, governor pressure is metered. As the vehicle's speed continues to increase, the weight assembly will be at a point at which governor pressure is acting on the left side of the reaction area of the valve. This produces sufficient force to compress the spring and allow the outer weight to move out against the outer governor body retaining ring. At a very high speed, the governor valve will be opened as far as possible. In this condition, it is possible for governor pressure to meet, but not to exceed, line pressure. Generally governor pressure ranges from 0 - 100 psi from idle to maximum speed, and rises proportionally with the increase in output shaft speed. Governor pressure and throttle pressure are acting upon the shift valves to determine when a shift will occur. Governor pressure is a direct indication of road speed, and throttle pressure is an indication of engine load. When both parameters have been met by the throttle and governor pressures, an upshift or downshift will occur. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 2943 Governor: Service and Repair CLEANING Thoroughly clean all the governor parts in a suitable cleaning solution but do not use any type of caustic cleaning agents. The governor weight components and the governor valve, must slide freely in their bores when clean and dry. Minor surface scratches and burrs can be smoothed with crocus cloth. INSPECTION The aluminum governor valve and outer weight have a hard coating on them. Check condition of this coating carefully. Do not reuse either part if the coating is damaged. Inspect the governor weight spring for distortion. Replace the spring, if distorted, collapsed, or broken. Clean the filter in solvent and dry it with compressed air. Replace the filter, if damaged. Inspect the park gear for chipped or worn gear teeth or damaged ring grooves. Replace the gear, if damaged. Check the teeth on the park gear for wear or damage. Replace the gear if necessary. Inspect the metal seal rings on the park gear hub. Replace the rings only if severely worn, or broken. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair Planetary Gears: Service and Repair PLANETARY GEARTRAIN DISASSEMBLY 1. Remove snap ring and #4 thrust washer (Fig. 178) 2. Remove annulus gear support front snap ring (Fig. 179). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Page 2947 3. Remove annulus gear support and snap ring (Fig. 180). 4. Remove remaining snap ring (Fig. 181). 5. Remove and inspect front planetary carrier assembly (Fig. 182). ASSEMBLY Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Page 2948 1. Install front planetary gear assembly to annulus gear (Fig. 183). 2. Install first support snap ring (Fig. 184). 3. Install annulus gear support and snap ring (Fig. 185). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Page 2949 4. Install a NEW front planetary gear snap ring and #4 thrust washer (Fig. 186). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams Transmission Control Module: Diagrams Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 2954 Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL The pump oil seal can be replaced without removing the pump and reaction shaft support assembly from the transaxle case. 1. Screw seal remover Tool C-3981-B into seal (Fig. 187), then tighten screw portion of tool to withdraw the seal. INSTALLATION The pump oil seal can be replaced without removing the pump and reaction shaft support assembly from the transaxle case. 1. To install a new seal, place seal in opening of the pump housing (lip side facing inward). Using Tool C-4193 and Handle Tool C-4171, drive new seal into housing until tool bottoms (Fig. 188). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 2965 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 2966 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 2967 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2971 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2972 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2973 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2974 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 2982 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 2983 Shift Interlock Cable: Service and Repair SHIFT INTERLOCK CABLE REMOVAL 1. Disconnect the battery negative cable. 2. Loosen set screw and remove knob from shifter handle (Fig. 202). 3. Remove the center console assembly as shown in (Fig. 203). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 2984 4. Remove shifter bezel (Fig. 204). 5. Disconnect the shifter/ignition interlock cable from the shifter lever and bracket as shown in (Fig. 205). 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 206). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 2985 7. Remove the steering column upper and lower shrouds (Fig. 207). 8. Disconnect the Brake Transmission Shift Interlock (BTSI) solenoid connector from the interlock cable (Fig. 208). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 2986 9. Rotate the ignition key to the "OFF" or "ON/ RUN" position (Fig. 209). 10. Squeeze the interlock cable locking tab. Remove the cable from the interlock housing (Fig. 210). 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. 209). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 2987 3. Install the interlock cable into the interlock housing at the steering column (Fig. 211). Verify the cable snaps into the housing and is fully seated. 4. Return the ignition key to the "LOCK" position (Fig. 209). 5. Connect the BTSI solenoid connector (Fig. 208). 6. Install cable into retaining clips as shown in (Fig. 208). 7. Install steering column upper and lower shrouds (Fig. 207). 8. Install steering column lower cover (Fig. 206). 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. 205). 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 follows: 13. Install shifter bezel 204. 14. Install center console assembly 203. 15. Install gearshift knob and tighten set screw to 2 Nm (15 inch lbs.) torque 202. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 2991 Brake Transmission Shift Interlock Solenoid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 2995 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 2996 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 2997 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments ADJUSTMENT 1. Loosen set screw and remove knob from shifter handle (Fig. 172). 2. Remove the center console assembly as shown in (Fig. 173). 3. Adjust gearshift cable as follows: a. Place gearshift lever in the PARK (P) position. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3002 b. Loosen shift cable adjustment screw (Fig. 174). 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 inch 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. 173). 6. Install gearshift knob and tighten set screw to 2 Nm (15 inch lbs.) torque (Fig. 172). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3003 Shift Cable: Service and Repair REMOVAL 1. Loosen set screw and remove knob from shifter handle (Fig. 163). 2. Remove the center console assembly as shown in (Fig. 164). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3004 3. Remove shifter bezel (Fig. 165). 4. Disconnect shift cable from shifter assembly as shown in (Fig. 166). 5. Remove three grommet plate to floor pan nuts as shown in (Fig. 166). 6. Disconnect both battery cables, remove battery hold down clamp and bolt, and remove battery. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3005 7. Remove air cleaner/throttle body assembly (Fig. 167)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. 167) and partially remove air cleaner assembly. d. Disconnect accelerator and speed control (if equipped) cables after the assembly 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. 168). 10. Raise vehicle on hoist. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3006 11. Remove catalytic converter heat shield (Fig. 169). 12. Remove intermediate pipe heat shield front bolts. 13. Remove remaining grommet plate screw and remove cable assembly from vehicle (Fig. 170). INSTALLATION 1. Install cable assembly through floor pan opening and secure to floor pan with grommet plate and one screw (Fig. 170). Make sure the three grommet plate studs protrude through cable assembly and floor pan and tighten screw to 7 Nm (60 inch 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. 169). 5. Install gear shift cable to bracket and connect to shift lever (Fig. 168). 6. Install and tighten the three grommet plate-to floor pan nuts. Tighten to 6 Nm (50 inch lbs.) torque. 7. Connect gearshift cable to shifter assembly as shown in (Fig. 166). 8. Install shifter bezel (Fig. 165). 9. Adjust gearshift cable as follows: a. Place gearshift lever in the PARK (P) position. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3007 b. Loosen shift cable adjustment screw (Fig. 171). 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 inch lbs.) torque. 10. Install battery tray. 11. Install battery and hold down clamp. 12. Install the air cleaner/throttle body assembly (Fig. 167)as follows: a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assembly 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. 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. 13. Install center console assembly (Fig. 164). 14. Install gearshift knob and tighten set screw to 2 Nm (15 inch lbs.) torque (Fig. 163). 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments Throttle Valve Cable/Linkage: Adjustments THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE The transmission throttle valve is operated by a cam on the valve body throttle lever. The throttle lever is actuated by a cable connected to the engine throttle body lever. The throttle valve is located within the transaxle valve body and is responsible for transaxle shift speed, shift quality, and part-throttle downshift sensitivity. Proper cable adjustment is essential for proper transaxle operation. NOTE: The air cleaner/throttle body assembly must be installed into position before making this adjustment. 1. Verify cable is routed properly with no kinked or binding conditions. 2. Release adjustment locking clip on cable at throttle body. It is not necessary to remove clip. 3. Grab cable conduit near adjustment body, push in towards throttle body, then release grip (Fig. 225). This allows cable to self adjust. 4. Press locking clip to secure cable position (Fig. 226). 5. Road test vehicle to verify proper transaxle operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Page 3011 Throttle Valve Cable/Linkage: Service and Repair REMOVAL 1. Remove air cleaner/throttle body assembly (Fig. 222) 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. 222) and partially remove air cleaner assembly (leave cables attached). NOTE: Pay attention to throttle valve cable routing before removal so it can be re-installed in the same manner. For proper transaxle operation, the cable must not bind. 2. Disconnect throttle valve cable from air cleaner/throttle body assembly as shown in (Fig. 223). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Page 3012 3. Disconnect throttle valve cable from lever on transaxle and remove from bracket (Fig. 224). INSTALLATION NOTE: Route throttle valve cable in a manner that allows free, unobstructed travel. For proper transaxle operation, the cable must not bind. 1. Install transaxle throttle valve cable to bracket and lever as shown in (Fig. 224). Make sure the cable snaps on to the lever. 2. Install the throttle valve cable to the air cleaner/throttle body as shown in (Fig. 223). 3. Install the air cleaner/throttle body assembly as follows: a. 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. b. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 Nm (40 inch lbs.) torque. c. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors. d. Connect proportional purge solenoid (PPS) and crankcase vent hose from throttle body. 4. Connect the battery negative cable. 5. Perform the Throttle Valve Cable Adjustment Procedure found in this group. 6. Road test vehicle and verify proper transaxle operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3016 Torque Converter: Description and Operation DESCRIPTION The torque converter (Fig. 227) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the fluid cooler and lines. IMPELLER Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3017 The impeller (Fig. 228) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving member of the system. TURBINE Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3018 The turbine (Fig. 229) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3019 The stator assembly (Fig. 230) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 231). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 232) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. torque multiplication effect of the torque converter necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle speed and throttle position. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch will engage at approximately 56 km/h (35 mph) with light throttle, after the shift to third gear. OPERATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3020 The converter impeller (Fig. 233) (driving member) which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 234). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" directing before it enters the impeller. This circulations of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3021 maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such a way as to cause it to lock-up is no longer doing so. In this condition of operations, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston to the front cover's friction material, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Control Module (PCM). The engagement cannot be activated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle speed and throttle position. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch will engage at approximately 56 km/h (35 mph) with light throttle, after the shift to third gear. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3022 Torque Converter: Service and Repair REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary, The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 235). Surface of converter lugs should be 1/2 in. to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3026 Throttle Converter Clutch Solenoid (ATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications Structural Collar to Oil Pan Bolts Step 1 30 in.lb Structural Collar to Transaxle Bolts Step 2 80 ft.lb Structural Collar to Oil Pan Bolts Step 3 40 ft.lb Final Torque Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications > Page 3030 Torque Converter Cover: Service and Repair REMOVAL 1. Raise vehicle on hoist. NOTE: To remove transaxle dust cover, the front bending strut must be removed. 2. Remove structural collar from oil pan to transaxle (Fig. 91). INSTALLATION CAUTION: The torque procedure for the structural collar must be followed, as damage to oil pan or collar could occur. 1. Install the structural collar (Fig. 91) using the following 3 step torque sequence: - Step 1: Install the collar to oil pan bolts and tighten to 3 Nm (30 inch lbs.). - Step 2: Install collar to transaxle bolts and tighten to 108 Nm (80 ft. lbs.). - Step 3: Final torque the collar to oil pan bolts to 54 Nm (40 ft. lbs.). 2. Lower vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Fitting, Transaxle Oil Cooler-To-Case 60 in.lb Screw, Cooler Bypass Valve-To-Transfer Plate 40 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Transmission Cooler Transmission Cooler: Description and Operation Transmission Cooler DESCRIPTION Oil coolers are internal oil to coolant type, mounted in the radiator lower tank (Fig. 2). Rubber oil lines connect the oil cooler and the automatic transmission. Use only approved transmission oil cooler hoses that are molded to fit the applicable vehicle. OPERATION As oil flows through the cooler, heat from the oil is transferred to the coolant. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Transmission Cooler > Page 3039 Transmission Cooler: Description and Operation Cooler Bypass Valve COOLER BYPASS VALVE DESCRIPTION The cooler bypass valve consists of an integrated check ball and spring, and a return tube (Fig. 106). It is fastened to and seals to the valve body transfer plate (Fig. 107). OPERATION The cooler bypass valve (Fig. 106) is designed to bypass the transaxle oil cooler circuit in cold weather conditions, or when circuit restrictions exceed Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Transmission Cooler > Page 3040 25-30 p.s.i. The integrated return tube carries bypassed oil back to the oil pump. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Page 3041 Transmission Cooler: Testing and Inspection TRANSMISSION OIL COOLER FLOW TESTING To determine proper transmission oil flow through the oil cooler perform the following procedure: 1. At the external cooler location, disconnect the "from cooler" hose. 2. Using Special Tool adaptors 6906-1-3 with a 9 mm (3/8 inch) transmission hose attached to one adapter, connect Special Tool 8392 flow meter in-series with the oil cooler flow circuit (Fig. 1). 3. Start engine and observe the flow meter gauge. 4. If oil flow is below minimum specifications, further diagnosis must be performed. a. Perform Oil Pump Volume Check. b. If oil pump volume is within specification, a possible restriction in the cooler lines or cooler has occurred. c. If oil pump volume is not within specification, possible internal transmission restrictions, component wear or damage has occurred. d. If an oil cooler restriction is suspected, perform further inspections and flow meter testing by isolating components (i.e. lines, coolers). e. After a restriction is isolated, perform cooler flush procedure. f. Re-test cooler flow. If cooler flow does not exceed minimum specification, replace component(s) as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Cooler Transmission Cooler: Service and Repair Automatic Transmission Cooler REMOVAL The transmission cooler in serviced with the radiator assembly. CLEANING Check the external cooler for debris on the cooling fin surfaces. Clean as necessary. 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. INSTALLATION The transmission cooler in serviced with the radiator assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Cooler > Page 3044 Transmission Cooler: Service and Repair Flushing Coolers and Tubes 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 AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. 1. Remove cover plate filler plug on Tool 6906. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Use Mopar(R) 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(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3048 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3049 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3050 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3051 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Screw, Valve Body-To-Transfer Plate 45 in.lb Bolt, Valve Body-To-Case 105 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3058 Valve Body: Description and Operation SOLENOID - TCC DESCRIPTION The Torque Converter Clutch (TCC) solenoid is fastened to the transaxle valve body, and its connector protrudes through the transaxle case (Fig. 220). OPERATION The torque converter clutch solenoid is responsible for controlling application of the torque converter clutch. It is controlled by the Powertrain Control Module (PCM), which determines when conditions are acceptable for torque converter lock-up. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3059 Valve Body: Adjustments HYDRAULIC CONTROL PRESSURE ADJUSTMENTS LINE PRESSURE An incorrect throttle pressure setting will cause incorrect line pressure readings even though line pressure adjustment is correct. Always inspect and correct throttle pressure adjustment before adjusting the line pressure. The approximate adjustment for line pressure is 1-5/16 inches, measured from valve body to inner edge of adjusting nut. However, due to manufacturing tolerances, the adjustment can be varied to obtain specified line pressure. The adjusting screw may be turned with an Allen wrench. One complete turn of adjusting screw changes closed throttle line pressure approximately 1-2/3 psi. Turning adjusting screw counterclockwise increases pressure, and clockwise decreases pressure. THROTTLE PRESSURE Throttle pressures cannot be tested accurately; therefore, the adjustment should be measured if a malfunction is evident. 1. Insert gauge pin of Tool C-3763 between the throttle lever cam and kickdown valve. 2. By pushing in on tool, compress kickdown valve against its spring so throttle valve is completely bottomed inside the valve body. 3. While compressing spring, turn throttle lever stop screw with adapter C-4553. Turn until head of screw touches throttle lever tang, with throttle lever cam touching tool and throttle valve bottomed. Be sure adjustment is made with spring fully compressed and valve bottomed in the valve body. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 VALVE BODY REMOVAL 1. Disconnect battery negative cable. 2. Disconnect throttle valve cable from throttle valve lever at transaxle. 3. Disconnect gearshift cable from gearshift lever at transaxle. 4. Disconnect torque converter clutch solenoid connector. 5. Raise vehicle on hoist. 6. Remove transaxle oil pan bolts (Fig. 295). 7. Separate oil pan from case and drain fluid into suitable container (Fig. 296). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3062 8. Remove oil filter-to-valve body screws (Fig. 297). 9. Remove oil filter and gasket (Fig. 298). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3063 10. Remove cooler bypass valve from valve body (Fig. 299). 11. Remove park rod e-clip, (Fig. 300). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3064 12. Remove park rod from valve body (Fig. 301). 13. Remove valve body-to-transaxle case bolts (Fig. 302). 14. Remove valve body from transaxle. Note orientation of governor tubes (Fig. 303). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3065 Valve Body: Service and Repair Disassembly DISASSEMBLY CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. NOTE: TAG ALL SPRINGS AS THEY ARE REMOVED FOR REASSEMBLY IDENTIFICATION. 1. Remove detent spring-to-valve body screws and remove spring (Fig. 304). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3066 2. Remove valve body-to-separator plate screws (Fig. 305) (Fig. 306). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3067 3. Separate transfer and separator plate from valve body assembly (Fig. 307). Note check ball locations (Fig. 308) for proper reassembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3068 4. Remove throttle valve shaft-to-manual valve shaft e-clip (Fig. 309). Note orientation of washer and seal (Fig. 310). 5. Remove manual valve shaft/lever from throttle valve shaft (Fig. 311). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3069 6. Remove throttle valve lever/shaft (Fig. 312). 7. Remove manual valve from valve body (Fig. 313). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3070 8. Remove pressure regulator spring retainer/adjusting screw bracket (Fig. 314). 9. Remove springs and valves as shown in (Fig. 315). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3071 10. Remove governor plugs as shown in (Fig. 316). 11. Remove torque converter clutch solenoid, spring, and plug as shown in (Fig. 317). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3072 12. Remove shift/shuttle valves and springs as shown in (Fig. 318). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3073 Valve Body: Service and Repair Cleaning and Inspection CLEANING Clean the valve body components in a parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Dry the parts with compressed air. Make sure all passages are clean and free from obstructions. NOTE: Do not use rags or shop towels to wipe off valve body components. Lint from these materials will adhere to the valve body components. Lint will interfere with valve operation and may clog filters and fluid passages. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with crocus cloth. The cloth should be in sheet form and be positioned on a surface plate, sheet of plate glass, or equally flat surface. However, if distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. CAUTION: Many of the valve body valves and plugs are made of coated aluminum. Aluminum components can be identified by the dark color of the special coating applied to the surface (or by testing with a magnet). DO NOT polish or sand aluminum valves or plugs with any type of material, or under any circumstances. This practice might damage the special coating and cause the valves and plugs to stick and bind. Aluminum valves and plugs should not be sanded or polished under any circumstances. However, minor burrs or scratches on steel valves and plugs can be removed with crocus cloth but do not round off the valve or plug edges. Squareness of these edges is vitally important. These edges prevent foreign matter from lodging between the valves, plugs and bore. INSPECTION Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Also inspect the coating on the aluminum valves and plugs. If the coating is damaged or worn through, the valve (or valve body) should be replaced. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3074 Valve Body: Service and Repair Assembly ASSEMBLY 1. Install shift/shuttle valves and springs as shown in (Fig. 318). 2. Install torque converter clutch solenoid, spring, and plug as shown in (Fig. 317). 3. Install governor plugs as shown in (Fig. 316). 4. Install pressure regulator and manual control springs and valves as shown in (Fig. 315). 5. Install pressure regulator spring retainer/adjusting screw bracket (Fig. 319). 6. Install manual valve from valve body (Fig. 320). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3075 7. Install throttle valve lever/shaft (Fig. 321). 8. Install manual valve shaft/lever to throttle valve shaft (Fig. 322). Align manual valve lever to manual valve. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3076 9. Remove throttle valve shaft-to-manual valve shaft seal, washer, and e-clip (Fig. 323). Verify that manual valve lever is engaged with manual valve. 10. Install and verify proper location of check balls (Fig. 324). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3077 11. Install transfer and separator plate to valve body assembly (Fig. 325). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3078 12. Using Tool L-4553 or equivalent (Fig. 326), install and torque valve body-to-transfer plate screws (Fig. 327) to 5 Nm (40 inch lbs.) torque. 13. Install detent spring into position. Install and torque detent spring-to-valve body screws to 5 Nm (40 inch lbs.) torque (Fig. 328). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3079 Valve Body: Service and Repair Installation INSTALLATION 1. Install valve body to transaxle. Position governor tubes into case (Fig. 329). 2. Install valve body-to-case bolts (Fig. 330) and torque to 12 Nm (105 inch lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3080 3. Install cooler bypass valve and seal (Fig. 331). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3081 4. Install park rod to valve body and install e-clip (Fig. 332) (Fig. 333). 5. Install oil filter and gasket (Fig. 334). 6. Install oil filter-to-valve body screws (Fig. 335) to 5 Nm (45 inch lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal > Page 3082 7. Install a bead of Mopar(R) Silicone Rubber Adhesive Sealant to oil pan (Fig. 336) and immediately install to case. 8. Install and torque oil pan-to-transaxle bolts (Fig. 337) to 19 Nm (165 inch lbs.). 9. Lower vehicle. 10. Connect torque converter clutch solenoid. 11. Connect gearshift cable to manual valve lever. 12. Connect throttle valve cable to throttle valve lever at transaxle. 13. Connect battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation Clutch Disc: Description and Operation MODULAR CLUTCH DESCRIPTION The modular clutch assembly (Fig. 23) is serviced only as an assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3087 Clutch Disc: Service and Repair 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 assembly (Fig. 24) 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. 24) and partially remove air cleaner assembly. e. Disconnect accelerator and speed control (if equipped) cables after the assembly 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3088 7. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 25) (Fig. 26). 8. Remove shift cable-to-bracket clips (Fig. 27). 9. Disconnect shift selector and crossover cable from levers (Fig. 27). Remove cables and secure out of the way. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3089 10. Disconnect the vehicle speed sensor connector (Fig. 28). 11. Raise vehicle on hoist. 12. Remove transaxle oil drain plug and drain oil into a suitable container. 13. Remove both axle shafts. 14. Remove structural collar (Fig. 29). 15. Remove the left engine-to-transaxle lateral bending brace (Fig. 29). 16. Remove bellhousing dust cover (Fig. 29). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3090 17. Remove the right engine-to-transaxle lateral bending brace (Fig. 30). 18. Remove starter motor (Fig. 31). 19. Remove drive plate-to-clutch module bolts. 20. Support engine at oil pan with screw jack and wood block. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3091 21. Remove transaxle upper mount thru-bolt. Gain access to this bolt through the driver's side wheel house (Fig. 32). 22. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained. 23. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts (Fig. 33). 24. Remove transaxle from vehicle (Fig. 33). 25. Remove modular clutch assembly from transaxle input shaft. INSPECTION Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation. During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/ road splash on clutch components. OIL Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Page 3092 GREASE Grease contamination is usually a product of over lubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc. ROAD SPLASH WATER Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel. Extreme use of steam cleaning equipment on the engine compartment or vehicle undercarriage can have the same effect. INSTALLATION 1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. 2. Install clutch module onto input shaft. Install transaxle into position. 3. Install transaxle-to-engine mounting bolts (Fig. 33) and tighten to 95 Nm (70 ft. lbs.) torque. 4. 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. 32). 5. Remove screw jack. 6. Install NEW drive plate-to-clutch module bolts and progressively tighten all bolts in a criss-cross pattern until the modular clutch assembly seats against the drive plate. Final torque the bolts to 88 Nm (65 ft. lbs.) torque. 7. 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. 31). 8. Connect starter electrical harness and tighten positive cable nut to 10 Nm (90 inch lbs.) torque. 9. Install bellhousing dust cover (Fig. 29). 10. Install left engine-to-transaxle bending brace (Fig. 29). 11. Install structural collar (Fig. 29) as follows: a. Position collar and install all bolts finger tight. b. Tighten the collar-to-oil pan bolts to 3 Nm (30 inch lbs.) torque. c. Tighten the collar-to-transaxle bolts to 108 Nm (80 ft. lbs.) torque. d. Final torque the collar-to-oil pan bolts to 54 Nm (40 ft. lbs.) torque. 12. Install the right lateral bending brace and tighten bolts to 81 Nm (60 ft. lbs.) torque (Fig. 30). 13. Install both front axle driveshafts. 14. Fill transaxle with suitable amount of Mopar(R) Manual Transaxle Lubricant (PN 04874465). 15. Lower vehicle. 16. Connect vehicle speed sensor connector (Fig. 28). 17. Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 27). 18. 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. 19. Connect back-up lamp switch connector. 20. Connect ground strap to transaxle upper mount bracket. 21. Install battery lower tray and battery, and tighten battery hold down clamp to secure battery. 22. Install the air cleaner/throttle body assembly as follows: a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assembly 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. 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. 23. Connect the battery cables. 24. Road test vehicle and inspect for leaks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Hydraulic Fluid DOT 3 Brake Fluid Conforming to J1703 Standards Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 70 in.lb Master Cylinder Mounting Nuts 300 in.lb Master Cylinder Reservoir Mounting Screws 24 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 3100 Clutch Master Cylinder: Description and Operation DESCRIPTION The clutch master cylinder mounts to the cowl (Fig. 14). The master cylinder consists of a push rod, a piston and cylinder housing, a remote fluid reservoir, and an interconnecting hydraulic tube (Fig. 15). OPERATION The clutch master cylinder (Fig. 15) 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 fork and clutch release bearing, disengaging the clutch. When the clutch pedal is released, pressure is relieved and the return spring returns the piston to its original position until the next pedal actuation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 3101 Clutch Master Cylinder: Service and Repair REMOVAL NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required. 1. Remove air cleaner assembly (Fig. 16). 2. Disconnect battery negative cable. 3. Raise vehicle on hoist. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 3102 4. Using Tool 6638A, disconnect clutch hydraulic quick-connect (Fig. 18) (Fig. 17). 5. Remove hydraulic hose from left rail retainer (Fig. 21). 6. Lower vehicle. 7. Remove PDC bracket and position out of way. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 3103 8. Remove lower instrument panel bezel (Fig. 19). 9. Remove clip and disconnect the brake booster input rod from the brake pedal pin (Fig. 20). 10. Remove the brake booster mounting nuts (Fig. 20). 11. Slide brake booster forward enough to gain access to and remove clutch master cylinder. 12. Remove clutch master cylinder reservoir (Fig. 21). 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 bulkhead 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. 21). If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance. INSTALLATION 1. Install the master cylinder into position on the dash panel. 2. Install the bulkhead connector bracket. 3. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 34 Nm (300 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 3 Nm (24 inch lbs.). 8. Install the brake booster. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 3104 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. Loosen the push rod adjustment screw (Fig. 22) and gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 8 Nm (70 inch lbs.). 11. Install the ABS module/purge solenoid, PDC, and air cleaner. 12. 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. 13. Connect the negative battery cable. 14. Verify correct clutch operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Description and Operation Clutch Slave Cylinder: Description and Operation CYLINDER DESCRIPTION The clutch slave cylinder is fastened to transaxle bellhousing (Fig. 34), and consists of a hydraulic piston and cylinder, seal, return spring, and integral fluid damper and line (Fig. 35). 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. 35) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Description and Operation > Page 3108 Clutch Slave Cylinder: Service and Repair REMOVAL NOTE: Replacement slave cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required. 1. Raise vehicle on hoist. 2. Disconnect clutch hydraulic quick connect using tool 6638A (Fig. 36). 3. Remove damper bracket nuts (Fig. 37). 4. Remove slave cylinder mounting bolts (Fig. 37). 5. 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. 1. Install the slave cylinder assembly into position on transaxle (Fig. 37). Start damper and slave cylinder fasteners by hand. 2. Tighten slave cylinder bolts to 19 Nm (170 inch lbs.) torque. 3. Tighten damper nuts to 23 Nm (200 inch lbs.) torque. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Description and Operation > Page 3109 4. Connect clutch hydraulic supply tube (Fig. 37). An audible click should be heard. Verify connection by pulling outward. 5. Lower vehicle. 6. Verify clutch master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary. 7. Actuate clutch pedal a minimum of ten times to allow any air ingested into the system to vent to the master cylinder reservoir. 8. Verify proper clutch release system operation. 9. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch Pedal Pivot Shaft Nut 25 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation DESCRIPTION The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 4). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 5), each switch being fastened by four plastic wing tabs. OPERATION CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch engaged and the transaxle in gear. The switch is open while the clutch pedal is at rest. When the clutch pedal is fully depressed, the pedal blade 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3116 Clutch Switch: Testing and Inspection CLUTCH INTERLOCK/UPSTOP SWITCH The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 6). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 7), each switch being fastened by four plastic wing tabs. 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.) and for proper installation of the master cylinder push rod/bushing on the pedal pin. Also make sure the clutch pedal blade contacts and fully closes the switch. 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 with the interlock switch not depressed (clutch pedal at rest). There should be Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3117 no continuity between the terminals (open circuit). 5. Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm. (0.050 inch). The ohmmeter should show continuity (0 ohms). 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. 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 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. CLUTCH INTERLOCK/UPSTOP SWITCH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3118 Clutch Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 8). 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. 9). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3119 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 10). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 10). 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. 10). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 11) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3120 1. Install switches into the pedal bracket assembly as shown in (Fig. 11). Route harness as was prior to removal. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 34 Nm (25 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. 9). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 6. Connect clutch master cylinder pushrod. Loosen adjustment screw (Fig. 12) and gently lift clutch pedal upwards until the clutch pedal fully depresses the the upstop switch. Torque adjustment screw to 8 Nm (70 inch lbs.). 7. Connect interlock/upstop and stop lamp switch connectors. 8. Install left lower instrument panel bezel (Fig. 8). 9. Connect battery negative cable. 10. Verify proper switch operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 FORK 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 fork (Fig. 13), which moves the bearing into contact with the clutch cover diaphragm spring. OPERATION The release bearing is operated by the release fork. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Description and Operation > Page 3124 Clutch Release Bearing: Service and Repair RELEASE BEARING AND FORK REMOVAL Remove the transaxle from the vehicle. 1. Move the lever and bearing assembly to a vertical in-line position. Grasp the release lever with two hands in the pivot stud socket area. Pull with even pressure and the lever will pop off the pivot stud. Do not use a screwdriver or pry bar to pop off the lever. This may damage the spring clip on the lever. 2. As a unit, remove the fork from the bearing thrust plate. Be careful not to damage retention tabs on bearing. 3. Examine the condition of the bearing. It is pre-lubricated and sealed and should not be immersed in oil or solvent. 4. The bearing should turn smoothly when held in the hand under a light thrust load. A light drag caused by the lubricant fill is normal. If the bearing is noisy, rough, or dry, replace the complete bearing assembly with a new bearing. 5. Check the condition of the pivot stud spring clips on back side of clutch fork. If the clips are broken or distorted, replace the clutch fork. INSTALLATION 1. The pivot ball pocket in the fork, as well as the fork arms should be lubricated with grease prior to installation. 2. Assemble the fork to the bearing. The small pegs on the bearing must go over the fork arms. 3. Slide the bearing and fork assembly onto the input shaft bearing retainer, as a unit. 4. Snap the clutch fork onto the pivot ball. 5. Reinstall transaxle assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Description and Operation Clutch Release Fork: Description and Operation For further information regarding this component or the system it is a part of please refer to Throw-out Bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Description and Operation > Page 3128 Clutch Release Fork: Service and Repair For further information regarding this component or the system it is a part of please refer to Throw-out Bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Modular Clutch to Drive Plate Bolts 88 Nm (65 ft. lbs.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3142 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3143 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3144 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3145 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3146 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3152 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3153 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3154 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3155 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3156 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3157 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3158 Axle Shaft: Testing and Inspection HALFSHAFT DIAGNOSIS VEHICLE INSPECTION 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. The right inner tripod joint seal boot is made of silicone rubber; which will allow the weeping (sweating) of the joint lubricant to pass through it while in operation. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions. 1. Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. 2. Noise may also be caused by another component of the vehicle coming in contact with the halfshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or outer joint of the halfshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the halfshaft assembly. 3. A damaged or worn halfshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION 1. A worn or damaged halfshaft inner tripod joint. 2. A sticking tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. VIBRATION AT HIGHWAY SPEEDS 1. Foreign material (mud, etc.) packed on the backside of the wheel(s). 2. Out of balance front tires or wheels. 3. Improper tire and/or wheel runout. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3159 Axle Shaft: Service and Repair HALF SHAFT 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. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3160 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3161 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. NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3162 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. 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3163 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3164 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 PMW 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3165 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > Page 3166 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Constant Velocity Joint Boot: Service and Repair 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 trunions to prevent the rollers and needle bearings from failing away. 3. Slide the interconnecting shaft and spider assembly out of the tripod joint housing (Fig. 15). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3171 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3172 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3173 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3174 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3175 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. CAUTION: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3176 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3177 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3178 12. If seal boot uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using clamp locking tool, Snap-On(R) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3179 Constant Velocity Joint Boot: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3180 5. Remove large circlip (Fig. 34) from the interconnecting shaft before attempting to remove outer C/V joint sealing boot. 6. Slide failed sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3181 3. Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced hammer and tapping end of stub axle (with nut installed) until outer C/V joint is fully seated on interconnecting shaft (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3182 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3183 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Suspension Bearing Retainer Plate bolt 250 in.lb Driveshaft Hub Nut 180 ft.lb Wheel Mounting Nuts 100 ft.lb Rear Suspension Knuckle Retaining Nut 160 ft.lb Wheel Mounting Nuts 80 - 110 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 3188 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB/BEARING The wheel bearing and hub are pressed into the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front > Page 3191 Wheel Bearing: Description and Operation Rear HUB/BEARING DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front > Page 3192 The hub and bearing is mounted on the rear knuckle's spindle. The hub and bearing adapts the tire and wheel assembly to the knuckle. It's bearing allows the tire and wheel assembly to rotate freely on the vehicle. All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. The only serviceable components of the hub and bearing are the wheel mounting studs. If a vehicle is equipped with antilock brakes, the tone wheels for the rear wheel speed sensors are pressed onto the hub. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 3195 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING (REAR) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 3196 The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. With the wheel, disc brake rotor or brake drum removed, rotate the hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub and bearing will require replacement. The bearing is not serviceable alone. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLY (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. 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. 2. Using Remover, Special Tool 4150A, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3199 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3200 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3201 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 honoring when 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3202 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 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3203 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3204 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3205 Wheel Bearing: Service and Repair Rear REMOVAL 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 any retainer clips from the wheel mounting studs, then pull the brake drum off the hub and bearing. 4. 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. 5. Remove the dust cap from the hub and bearing assembly. 6. Remove the retaining nut, then the hub and bearing from the knuckle's spindle. INSTALLATION 1. 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.). 2. Install the dust cap on the end of the hub and bearing. 3. 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.). 4. 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.). 5. Lower the vehicle to ground level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Driveshaft-to-Hub/Bearing 180 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Bolt, Drive Plate-To-Crankshaft 70 ft.lb Bolt, Drive Plate-To-Torque Converter 50 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 3213 Flex Plate: Service and Repair REMOVAL 1. Remove the transaxle. 2. Remove the flex plate attaching bolts (Fig. 78). 3. Remove the flex plate (Fig. 78). INSTALLATION 1. Position the drive plate on crankshaft (Fig. 78). 2. Apply Mopar(R) Lock & Seal Adhesive to flex plate bolt threads. 3. Install the flex plate bolts and tighten to 95 Nm (70 ft. lbs.) (Fig. 78). 4. Install the transaxle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Bolt, Drive Plate-To-Crankshaft 70 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Specifications Bell Housing: Specifications Transaxle To Engine Bolt 70 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Transaxle Case Bolts 21 ft.lb Dust Shield to Transaxle 105 in.lb End Plate Cover Bolts 21 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Adjustments Differential: Adjustments DIFFERENTIAL BEARING PRELOAD ADJUSTMENT / SHIM SELECTION Measure and adjust differential side bearing preload during any transaxle service, especially when the following components are replaced: - Transaxle gear case - Clutch bellhousing case - Differential case - Differential bearings NOTE: True bearing turning torque readings can be obtained only with the geartrain removed from the case. 1. Remove bearing cup and existing shim from clutch bellhousing case. 2. Press in new bearing cup into bellhousing case (or use a cup that, has been ground down on the outer edge for ease of measurement). 3. Press in new bearing cup into gear case side. 4. Oil differential bearings with Mopar(R) type M.S. 9417 Manual Transaxle Fluid. Install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and torque case bolts to 29 Nm (21 ft. lbs.). 5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator. NOTE: Indicator is set up as shown for illustrative purposes only (Fig. 88). Indicator must be parallel to T-Handle to obtain the most accurate reading. 6. Apply a medium load to differential with Tool C-4995 and a T-handle, in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator. To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth (Fig. 88). Record end play. 7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18 mm (0.007 inch). Never combine shims to obtain the required preload. 8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected in Step 7. Then press the bearing cup into clutch bellhousing. 9. Install clutch bellhousing. Install and torque case bolts to 26 Nm (19 ft. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Adjustments > Page 3227 10. Using Special Tool C-4995 and an inch-pound torque wrench, check turning torque of the differential assembly (Fig. 89). The turning torque should be 6 to 12 inch lbs. If the turning torque is too high, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thicker shim. 11. Recheck turning torque. Repeat Step 10 until the proper turning torque is obtained. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly Differential: Service and Repair Disassembly DISASSEMBLY 1. Remove differential bearing cones (ring gear and diff. case side) using Tool C-293-PA, Adapters C-293-45, and Tool 4996 (Fig. 68) (Fig. 69). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3230 2. Remove ring gear-to-case bolts (Fig. 70). Discard and use NEW bolts upon assembly. 3. Using a suitable screwdriver, pry off speedometer drive gear (Fig. 71) (Fig. 72). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3231 4. Using hammer and suitable punch, remove pinion shaft retaining pin (Fig. 73) (Fig. 74). 5. Remove pinion shaft (Fig. 75). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3232 6. Remove pinion gears, side gears, and thrust washers (Fig. 76) (Fig. 77). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3233 Differential: Service and Repair Assembly ASSEMBLY Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3234 1. Assemble side gears, pinion gears, and thrust washers (Fig. 77) into case through opening and rotating into position (Fig. 76). 2. Install pinion shaft (Fig. 75). 3. Using hammer and suitable punch, install pinion shaft retaining pin (Fig. 78). 4. Stake case to retain pin as shown in (Fig. 79). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3235 5. Using an arbor press, Handle C-4171, and Tool L-4410, install differential side bearings to ring gear and case side (Fig. 80) (Fig. 81). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3236 6. Install speedometer drive gear to case (Fig. 82). 7. Using an arbor press, steel block, and Tool L-4440, press speedometer drive gear onto differential case (Fig. 83) (Fig. 84). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3237 8. Install ring gear to differential case. Install new bolts and torque to 81 Nm (60 ft. lbs.) torque (Fig. 85). Measure and Adjust Side Gear End-Play Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3238 1. Rotate the assembly two full revolutions both clockwise and counterclockwise. Set up dial indicator as shown and record end play (Fig. 86) (Fig. 87). Rotate side gear 90 degrees and take another measurement. Again, rotate side gear 90 degrees and record a final measurement. 2. Using the smallest end play recorded, shim that side gear to within 0.001 to 0.013 inch. The other side gear should be checked using the same procedure. CAUTION: Side gear end play must be within 0.001 to 0.013 inch. Five select thrust washers are available: 0.027, 0.032, 0.037, 0.042, and 0.047 inch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Service and Repair > Disassembly > Page 3239 Differential: Service and Repair Differential Bearing Caps DIFFERENTIAL BEARING CUPS Removal 1. Remove differential assembly from gear case using the procedure outlined in this group. 2. Install Miller tool #L-4518 into the differential bearing cup (Fig. 90). 3. Install the tool cup over the tool (Fig. 91). 4. Tighten the tool until the race is removed from the case. Installation 1. Position the bearing cup into the case. 2. Install the bearing cup onto Miller tool #L-4520. 3. Using Miller tool #L-4520 and C-4171 driver, install differential bearing cup into the transaxle case. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain Plug 267 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transaxle NV T350 (A-578) ........................................................................................................................................ 2.4 2.7Liters (2.5 - 2.8 Qt) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3247 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type ................................................................................................................. Mopar ATF +4 Automatic Transmission Fluid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3248 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3249 Fluid - M/T: Service and Repair FLUID DRAIN AND FILL All NV T350 (A-578) 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). All NV T350 (A-578) 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 following chart. Wipe the outside of the transaxle if any lubricant spills. MV T350 (A-578) MANUAL TRANSAXLE FLUID FILL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Service and Repair > Disassembly Synchronizer Hub: Service and Repair Disassembly 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Service and Repair > Disassembly > Page 3255 Synchronizer Hub: Service and Repair Cleaning and Inspection SYNCHRONIZER CLEAN 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. INSPECT 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Service and Repair > Disassembly > Page 3256 Synchronizer Hub: Service and Repair Assembly SYNCHRONIZER 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. 4. Apply petroleum jelly to the hole in the key. Insert balls into each key (Fig. 148). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Service and Repair > Disassembly > Page 3257 5. Slide sleeve over the hub and depress balls as you carefully slip the sleeve into position (Fig. 149). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement Input Shaft: Service and Repair Input Shaft Bearing Replacement 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(R) sealant on bearing outer diameter. Position sleeve and bearing assembly at input bearing bore. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3262 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3263 Input Shaft: Service and Repair Input Shaft Replacement 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). 1. Install bearing splitter behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft (Fig. 112). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3264 2. Remove synchronizer and gear using shop press (Fig. 113). 3. Remove caged needle bearing (Fig. 114). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3265 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3266 7. Remove 4th gear (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3267 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3268 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3269 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3270 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Input Shaft Bearing Replacement > Page 3271 12. Install 5th gear synchronizer snap ring (Fig. 130). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Bearing and Race Output Shaft: Service and Repair Output Bearing and Race 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Bearing and Race > Page 3276 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Bearing and Race > Page 3277 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Bearing and Race > Page 3278 Output Shaft: Service and Repair Output Shaft Disassembly and Assembly 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair AXLE SEAL REMOVAL 1. Remove axle shaft. Refer to DRIVE AXLES AND RELATED BEARINGS, JOINTS for the correct procedures. 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. Refer to DRIVE AXLES AND RELATED BEARINGS, JOINTS for the correct procedures. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair Shifter M/T: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Page 3285 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Page 3286 6. Remove four shifter assembly-to-floor pan nuts and remove shifter from vehicle (Fig. 143). INSTALLATION 1. Install shifter assembly 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications Shift Cable: Specifications Crossover Cable Adj. Screw 70 in.lb Shift Cable Bracket To Transaxle 250 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3294 Shift Cable: Adjustments 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3295 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3296 Shift Cable: Service and Repair 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 assembly (Fig. 94). 4. Remove the center console assembly as shown in (Fig. 95). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3297 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3298 8. Remove air cleaner/throttle body assembly (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 assembly 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3299 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3300 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 assembly (Fig. 98) (Fig. 94) as follows: a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assembly 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Front Engine Mount To Trans 80 ft.lb Front Mount Through Bolt 45 ft.lb Front Mount To Engine Bolt 40 ft.lb Lateral Bending Strut To Engine 40 ft.lb Lateral Bending Strut To Trans. 40 ft.lb Vertical Bending Strut To Engine 80 ft.lb Vertical Bending Strut To Trans. 80 ft.lb Left Mount Through Bolt 80 ft.lb Left Mount To Transaxle 40 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams Transmission Control Module: Diagrams Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3312 Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Diagrams Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3321 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3322 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3323 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3327 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3328 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3329 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3330 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3340 Brake Transmission Shift Interlock Solenoid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3344 Throttle Converter Clutch Solenoid (ATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams Transmission Control Module: Diagrams Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3350 Transmission Control Module (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Diagrams Transmission Control System Relay: Diagrams Power Distribution Center Transmission Control Relay (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3359 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3360 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3361 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3365 Transmission Range Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3366 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3367 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3368 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 > Diagrams Transmission Speed Sensor: Diagrams Input Speed Sensor (EATX) Output Speed Sensor (EATX) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Application and ID 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Application and ID > Page 3377 ABS Light: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations Hydraulic Control Unit Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations Controller Antilock Brake: Locations Fig.1 Integrated Control Unit (ICU) HCU Location The CAB is mounted to the bottom of the HCU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 3384 Controller Antilock Brake: Diagrams Controller Antilock Brake Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 3385 Controller Antilock Brake: Description and Operation Fig.1 Integrated Control Unit (ICU) CONTROLLER ANTILOCK BRAKE The controller antilock brake (CAB) is a microprocessor-based device which monitors the ABS system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: monitor the antilock brake system for proper operation. - detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction control system is activated. - store diagnostic information. - provide communication to the DRBIII scan tool while in diagnostic mode. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will send a message to the Mechanical Instrument Cluster (MIC) instructing it to turn ON the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning lamp is turned ON and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. These DTC's will remain in the CAB memory even after the ignition has been turned OFF. The DTC's can be read and cleared from the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles of vehicle operation. Controller Antilock Brake Inputs Wheel Speed sensors (four) - Brake Lamp switch - Ignition Switch - System Relay Voltage - Ground - Traction Control Lamp Actuation - Diagnostic Communication (PCI) Controller Antilock Brake Outputs Amber ABS warning indicator lamp actuation (through MIC) - Red BRAKE warning indicator lamp actuation (through MIC) - Traction control lamp - Diagnostic communication. (PCI) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 3386 Controller Antilock Brake: Service and Repair REMOVAL To remove the CAB, the ICU must be removed from the vehicle and disassembled. INSTALLATION To install the CAB, it must be attached to the HCU, forming the ICU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Mounting Bolts 97 in.lb CAB Mounting Bolts 17 in.lb Bracket-to-frame Rail Bolts 200 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 3390 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 3391 Hydraulic Control Assembly - Antilock Brakes: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL - ICU NOTE: Before proceeding with this procedure, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3394 7. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs in the master cylinder outlet ports. 8. Disconnect the 25-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 25-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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3395 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 INTEGRATED CONTROL UNIT DISASSEMBLY. INSTALLATION - ICU NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Install the Integrated Control Unit (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 inch lbs.). 3. Install the four brake tubes going to the brakes into their respective outlet ports on the ICU Hydraulic Control Unit (HCU). Using a crow foot on a torque wrench, tighten the four brake tube nuts to a torque of 17 Nm (145 inch 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. 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 inch lbs.). CAUTION: Before installing the 25-way connector in the Controller Antilock Brake (CAB), be sure the seal is properly installed in the connector. 7. Install the 25-way connector into the socket of the CAB as follows: - Position the 25-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 inch 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 (106 inch 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 Antilock Brake System (ABS) hydraulic systems. 14. Fill the master cylinder to the proper fill level. 15. Road test the vehicle to ensure proper operation of the base and ABS. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3396 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly 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. CAB Attaching Bolts 2. Remove the 4 bolts attaching the CAB to the HCU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3397 3. Remove the CAB from the HCU. NOTE: For assembly, Refer to INTEGRATED CONTROL UNIT - ASSEMBLY. ASSEMBLY - ICU 1. Install the Controller Antilock Brake (CAB) on the Hydraulic Control Unit (HCU). 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the Integrated Control Unit (ICU) in the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensor Head Mounting Bolt 105 in.lb Front Tone Wheel Clearance Minimum 0.011 in Maximum 0.056 in Rear Tone Wheel Clearance Minimum 0.018 in Maximum 0.044 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 3409 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 3410 Wheel Speed Sensor: Connector Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3411 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Front Wheel Speed Sensor Connector (Sensor Side) Left Rear Wheel Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3412 Left Rear Wheel Speed Sensor Connector (Sensor Side) Right Front Wheel Speed Sensor Right Front Wheel Speed Sensor Connector (Sensor Side) Right Rear Wheel Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3413 Right Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3414 Wheel Speed Sensor: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component, Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Service Precautions. 1. Raise the vehicle. 2. Disconnect the Wheel Speed Sensor (WSS) 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. Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. 4. Remove the bolt mounting the WSS 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. 5. Carefully, remove the sensor head from the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3417 6. Remove the screw securing the WSS to the rear of the strut. Remove the WSS. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 (WSS) to the strut using the its mounting screw. 2. Install the WSS 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 WSS 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. Lower the vehicle. 6. Road test vehicle to ensure proper operation of the base brakes and Antilock Brake System (ABS). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3418 Wheel Speed Sensor: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Disconnect the Wheel Speed Sensor (WSS) cable connector from the vehicle wiring harness. Remove the clip attaching WSS cable connector to the vehicle's body. 3. Remove the WSS 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 WSS cable routing bracket to rear strut. CAUTION: When removing a WSS 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 WSS to the rear disc brake adapter, then carefully remove the sensor head from the rear disc brake adapter and Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3419 vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 (WSS) head into the disc brake adapter. 2. Install the WSS mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. Install the WSS cable routing bracket on the rear strut. 4. Install WSS cable into the routing clips on the rear brake hose and brake tube. 5. Connect the WSS cable connector into vehicle wiring harness. Install the clip attaching the WSS cable connector to vehicle's body. 6. Lower the vehicle. 7. Road test the vehicle to ensure proper operation of the base brakes and Antilock Brake System (ABS). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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. 3. Fill the brake fluid reservoir with Mopar brake fluid, or an 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. NOTE: It is not necessary to bleed the entire hydraulic system after replacing just the master cylinder unless the brake system has been open to air for an excessive amount of time or air is present in the lines. Only the master cylinder must be bled and filled. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3424 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the Antilock Brake System (ABS) hydraulic system, refer to ABS 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 having a bleeder screw open during the bleeding process. 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 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3425 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3426 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 Antilock Brake System (ABS) though, particularly the Integrated Control Unit (ICU) (Hydraulic Control Unit [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 (DLC). 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 Controller Antilock Brake (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal Ratio 3.41 : 1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 3430 Brake Pedal Assy: Service and Repair 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 clock spring 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 3431 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 Antilock Brake System (ABS) Integrated Control Unit (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 its 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. WITH MANUAL TRANSAXLE 1. Remove the instrument panel. 2. Remove the brake lamp switch. 3. Disconnect the clutch cable from the clutch pedal spacer. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 3432 4. Disconnect the wiring harness connector going to the clutch pedal switches. 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 its 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. 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 inch lbs.). 9. Tighten the two nuts fastening the brake pedal bracket to the instrument panel support to a torque of 34 Nm (300 inch 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 inch lbs.). Install the pinch bolt retainer pin. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 3433 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. WITH MANUAL TRANSAXLE 1. If the pedal has been removed from its 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 inch lbs.). 5. Tighten the two nuts fastening the brake pedal bracket to the instrument panel support to a torque of 34 Nm (300 inch lbs.). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Application and ID Brake Warning Indicator: Application and ID 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Application and ID > Page 3437 Brake Warning Indicator: Testing and Inspection 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Banjo Bolt 35 ft.lb Guid Pin Bolts 192 in.lb Bleeder Screw 125 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front REMOVAL - DISC BRAKE CALIPER (FRONT) 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 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. Inspect and discard these if they are worn or damaged. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3444 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. Rear 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3445 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. Inspect and discard these if they are worn or damaged. 5. Remove the two caliper guide pin bolts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3446 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. 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 Mopar Multi-purpose 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. 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 inch lbs.). 5. Install the banjo bolt connecting the brake hose to the brake caliper. Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Install new washers if they are worn or damaged at all. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3447 Brake Caliper: Service and Repair Disassembly and Assembly Front Disc Brake Caliper DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. 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. Removing Bushing From Caliper 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3448 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 in DISC BRAKE SHOES, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3449 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. Honing Brake Caliper Piston Bore 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. Do 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. ASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3450 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. Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper mounting boss using your finders. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3451 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3452 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3453 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: Before proceeding with this procedure, Refer to Service Precautions. 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 Mopar Multi-purpose 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3454 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 inch lbs.). 5. Install the banjo bolt connecting the brake hose to the brake caliper. Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Install new washers if they are worn or damaged at all. 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. Rear Disc Brake Caliper 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 in DISC BRAKE SHOES, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3455 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3456 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. DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3457 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). Removing Bushing From Caliper 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. ASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL) NOTE: Never use an old piston seal. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3458 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3459 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3460 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3461 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3462 Brake Caliper: Service and Repair Cleaning and Inspection Front Disc Brake Caliper 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 Mopar 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. Rear Disc Brake Caliper 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 Mopar 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Front Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or less, they should be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 3467 Brake Pad: Specifications Rear Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they should be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation Brake Pad: Service and Repair Removal and Installation Front REMOVAL - DISC BRAKE SHOES (FRONT) NOTE: Before proceeding with this procedure, Refer to Service Precautions. Vehicles that are equipped with optional four-wheel-disc brake system use a different lining material on the front disc brake shoes than vehicles with front disc and rear drum brakes. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3470 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. 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. INSTALLATION - DISC BRAKE SHOES (FRONT) NOTE: Before proceeding with this procedure, Refer to Service Precautions. Vehicles that are equipped with optional four-wheel-disc brake system use a different lining material on the front disc brake shoes than vehicles with front disc and rear drum brakes. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3471 3. Remove any protective paper from the noise suppression gasket on both the inner and outer brake shoes (if equipped). 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 Mopar Multi-purpose 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3472 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 inch 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 before moving the vehicle to set the brake shoes to the brake rotor. 13. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Rear REMOVAL - DISC BRAKE SHOES (REAR) 1. Raise the vehicle. 2. Remove both rear tire and wheel assemblies from vehicle. 3. Begin on one side of the vehicle. 4. Remove the two caliper guide pin bolts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3473 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. 6. Hang the brake caliper from rear strut using wire or cord to prevent the weight of the caliper from damaging the brake hose. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3474 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. 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. 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). 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 Mopar Multi-purpose 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3475 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 inch 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 several times to ensure the vehicle has a firm brake pedal before moving the vehicle. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3476 Brake Pad: Service and Repair Cleaning and Inspection Front 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 remove from. Rear 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 remove from. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 3480 Brake Rotor/Disc: Testing and Inspection For testing and inspection procedures for this component refer to Brakes, Testing and Inspection, Procedures. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Brake Rotor/Disc: Service and Repair 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 3483 Brake Rotor/Disc: Service and Repair 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. 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 136 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Drum Brake Shoe Support Plate Mounting Bolts 55 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 3488 Backing Plate: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 3489 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 3490 10. Position a 1/2 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 inch 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 inch 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 3496 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 3500 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 plug 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation Brake Shoe: Service and Repair Removal and Installation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 3503 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 3504 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 3505 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 3506 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. 8. Install the lower brake shoe-to-anchor plate return spring. 9. Install the automatic adjustment lever on the leading brake shoe. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal and Installation > Page 3507 Brake Shoe: Service and Repair Cleaning and Inspection 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Rear Mounting Bolts 115 in.lb Bleedier Screws 80 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 3511 Wheel Cylinder: Service and Repair 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 3512 8. 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 assembly. 2. Install the wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 13 Nm (115 inch 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 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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. 3. Fill the brake fluid reservoir with Mopar brake fluid, or an 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. NOTE: It is not necessary to bleed the entire hydraulic system after replacing just the master cylinder unless the brake system has been open to air for an excessive amount of time or air is present in the lines. Only the master cylinder must be bled and filled. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3518 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the Antilock Brake System (ABS) hydraulic system, refer to ABS 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 having a bleeder screw open during the bleeding process. 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 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3519 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3520 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 Antilock Brake System (ABS) though, particularly the Integrated Control Unit (ICU) (Hydraulic Control Unit [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 (DLC). 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 Controller Antilock Brake (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Banjo Bolt 35 ft.lb Guid Pin Bolts 192 in.lb Bleeder Screw 125 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front REMOVAL - DISC BRAKE CALIPER (FRONT) 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 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. Inspect and discard these if they are worn or damaged. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3526 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. Rear 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3527 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. Inspect and discard these if they are worn or damaged. 5. Remove the two caliper guide pin bolts. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3528 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. 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 Mopar Multi-purpose 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. 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 inch lbs.). 5. Install the banjo bolt connecting the brake hose to the brake caliper. Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Install new washers if they are worn or damaged at all. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3529 Brake Caliper: Service and Repair Disassembly and Assembly Front Disc Brake Caliper DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. 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. Removing Bushing From Caliper 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3530 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 in DISC BRAKE SHOES, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3531 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. Honing Brake Caliper Piston Bore 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. Do 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. ASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3532 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. Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper mounting boss using your finders. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3533 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3534 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3535 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: Before proceeding with this procedure, Refer to Service Precautions. 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 Mopar Multi-purpose 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3536 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 inch lbs.). 5. Install the banjo bolt connecting the brake hose to the brake caliper. Place one fitting washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Install new washers if they are worn or damaged at all. 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. Rear Disc Brake Caliper 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 in DISC BRAKE SHOES, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3537 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3538 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. DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS) Before disassembling the brake caliper, clean and inspect it. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3539 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). Removing Bushing From Caliper 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. ASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL) NOTE: Never use an old piston seal. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3540 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3541 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3542 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3543 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3544 Brake Caliper: Service and Repair Cleaning and Inspection Front Disc Brake Caliper 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 Mopar 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. Rear Disc Brake Caliper 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 Mopar 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 3548 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 3549 Brake Fluid: Description and Operation 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 an container which has been left open. An open container 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation For Description and Operation of this Component refer to Brakes, Description and Operation, System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 3553 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 Service Precautions. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Tube Nuts 145 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation For Description and Operation of this Component refer to Brakes, Description and Operation, System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 3560 Brake Proportioning/Combination Valve: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 Service Precautions. 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 40 Nm (30 ft. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bolts 97 in.lb CAB Mounting Bolts 17 in.lb Bracket-to-frame Rail Bolts 200 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 3564 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 3565 Hydraulic Control Assembly - Antilock Brakes: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL - ICU NOTE: Before proceeding with this procedure, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3568 7. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs in the master cylinder outlet ports. 8. Disconnect the 25-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 25-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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3569 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 INTEGRATED CONTROL UNIT DISASSEMBLY. INSTALLATION - ICU NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Install the Integrated Control Unit (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 inch lbs.). 3. Install the four brake tubes going to the brakes into their respective outlet ports on the ICU Hydraulic Control Unit (HCU). Using a crow foot on a torque wrench, tighten the four brake tube nuts to a torque of 17 Nm (145 inch 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. 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 inch lbs.). CAUTION: Before installing the 25-way connector in the Controller Antilock Brake (CAB), be sure the seal is properly installed in the connector. 7. Install the 25-way connector into the socket of the CAB as follows: - Position the 25-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 inch 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 (106 inch 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 Antilock Brake System (ABS) hydraulic systems. 14. Fill the master cylinder to the proper fill level. 15. Road test the vehicle to ensure proper operation of the base and ABS. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3570 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly 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. CAB Attaching Bolts 2. Remove the 4 bolts attaching the CAB to the HCU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3571 3. Remove the CAB from the HCU. NOTE: For assembly, Refer to INTEGRATED CONTROL UNIT - ASSEMBLY. ASSEMBLY - ICU 1. Install the Controller Antilock Brake (CAB) on the Hydraulic Control Unit (HCU). 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the Integrated Control Unit (ICU) in the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Mounting Nuts 250 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 3575 Brake Master Cylinder: Description and Operation For Description and Operation for this Component refer to Brakes, Description and Operation, System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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. 3. Fill the brake fluid reservoir with Mopar brake fluid, or an 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. NOTE: It is not necessary to bleed the entire hydraulic system after replacing just the master cylinder unless the brake system has been open to air for an excessive amount of time or air is present in the lines. Only the master cylinder must be bled and filled. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 3578 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation With ABS REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 Mopar 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 NOTE: Before proceeding with this procedure, Refer to Service Precautions. The master cylinder must be bled before installing it on the vehicle. 1. Bleed the master cylinder before installing it on the vehicle. 2. 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. 3. 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. 4. Install the two master cylinder mounting nuts. Tighten the mounting nuts to a torque of 28 Nm (250 inch lbs.). 5. 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 inch lbs.). 6. Install the wiring harness connector on the master cylinder reservoir fluid level switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 3579 7. Install the battery and clamp in place. 8. Connect the positive, then the negative (ground) cable on the battery. 9. Fill the master cylinder to the proper fill level. 10. Road test the vehicle to ensure proper operation of the base and Antilock Brake Systems (ABS). Without ABS REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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. 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 NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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. 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 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. 5. Install the two master cylinder mounting nuts and tighten each to a torque of 18 Nm (160 inch lbs.). 6. 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.). 7. Connect the brake fluid level switch wiring connector. 8. Install the battery and clamp it in place. 9. Connect the positive, then the negative (ground) cable on the battery. 10. Fill the master cylinder to the proper level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 3580 11. Road test the vehicle to ensure proper operation of the brakes. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 3581 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation REMOVAL NOTE: Before proceeding with this procedure, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 3582 6. Remove the grommets sealing the reservoir to the master cylinder housing. INSTALLATION NOTE: Before proceeding with this procedure, 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. Install new sealing grommets in the master cylinder housing. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Rear Mounting Bolts 115 in.lb Bleedier Screws 80 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 3586 Wheel Cylinder: Service and Repair 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 3587 8. 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 assembly. 2. Install the wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 13 Nm (115 inch 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 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair Parking Brake Cable: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3592 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 1/2 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3593 - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3594 - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3595 - Remove the parking brake cable from the rear brake support plate. The parking brake cable can be removed from brake support plate using a 1/2 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 1/2 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 inch 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3596 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. 6. On vehicles equipped with rear disc brakes: - 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. 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 inch 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking Brake Lever Mounting Nuts 250 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3600 Parking Brake Lever: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3601 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. 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. 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 inch 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3602 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments 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 than 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 3606 Parking Brake Shoe: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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. 10. Remove the adjuster assembly from the parking brake shoe assemblies. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 3607 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 3608 13. Remove the front brake shoe hold-down clip. Remove the front brake shoe assembly. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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. 10. Install the rear brake rotor. 11. Install rear disc brake caliper Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 3609 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Testing and Inspection Parking Brake Warning Lamp: Testing and Inspection 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Recalls for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement Technical Service Bulletin # 983 Date: 010601 Recall - Brake Booster Hose Replacement June 2001 Safety Recall No. 983 Brake Booster Vacuum Hose Models 2000-2001 (PL) Dodge and Plymouth Neon NOTE: This recall applies only to the above vehicles equipped with a: ^ 2.0L engine ("C" in the 8th VIN Position) built through March 21, 2001 (MDH 0321 XX) or a ^ 2.0L High Output engine ("F" in the 8th VIN Position) built through April 11, 2001 (MDH 0411XX). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The brake booster vacuum hose on about 350,000 of the above vehicles may swell due to oil contamination and become disconnected. A disconnected hose could cause a loss of power brake assist and an increase in engine idle speed. This can increase stopping distance and cause an accident without warning. Repair The brake booster vacuum hose must be replaced. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Booster Vacuum Hoses to service about 10% of those vehicles. Dealers should determine which brake booster vacuum hose is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The vacuum hose 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 > Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. 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 recall service completions and provide dealer payments. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Recalls for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement > Page 3622 Use the labor operation number and time allowance shown. Add the cost of the hose plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles 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, then type "0RD983". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. For most vehicles, this repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. 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 Zone Service Office. Service Procedure 1. For Neon R/T vehicles equipped with a 2.0L High Output engine: Raise the vehicle on an appropriate hoist. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Recalls for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement > Page 3623 2. Disconnect the brake booster vacuum hose from the intake manifold nipple (Figure 1). NOTE: On Neon R/T vehicles, the intake manifold nipple is located on the rear of the manifold between the # 2 and # 3 cylinder runners. 3. For Neon R/T vehicles equipped with a 2.0L High Output engine: Lower the vehicle. 4. Disconnect the brake booster vacuum hose from the check valve on the brake booster (Figure 2). Do not remove the check valve from the brake booster. IMPORTANT: For Neon R/T vehicles equipped with a 2.0L High Output engine, disconnect the brake booster hose from the inline hose connector located near the brake booster. Do NOT disconnect the vacuum hose elbow from the brake booster check valve. 5. Remove and discard the brake booster vacuum hose. 6. Route the new vacuum hose in the same location as the original hose and then secure the hose with the clips on the left side of the valve cover. 7. Connect the brake booster vacuum hose to the check valve on the brake booster (Figure 2) or to the inline hose connector (Neon R/T vehicles). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Recalls for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement > Page 3624 8. Connect the brake booster vacuum hose to the intake manifold nipple (Figure 1). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement Technical Service Bulletin # 983 Date: 010601 Recall - Brake Booster Hose Replacement June 2001 Safety Recall No. 983 Brake Booster Vacuum Hose Models 2000-2001 (PL) Dodge and Plymouth Neon NOTE: This recall applies only to the above vehicles equipped with a: ^ 2.0L engine ("C" in the 8th VIN Position) built through March 21, 2001 (MDH 0321 XX) or a ^ 2.0L High Output engine ("F" in the 8th VIN Position) built through April 11, 2001 (MDH 0411XX). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The brake booster vacuum hose on about 350,000 of the above vehicles may swell due to oil contamination and become disconnected. A disconnected hose could cause a loss of power brake assist and an increase in engine idle speed. This can increase stopping distance and cause an accident without warning. Repair The brake booster vacuum hose must be replaced. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Booster Vacuum Hoses to service about 10% of those vehicles. Dealers should determine which brake booster vacuum hose is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The vacuum hose 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 > Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. 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 recall service completions and provide dealer payments. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement > Page 3630 Use the labor operation number and time allowance shown. Add the cost of the hose plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles 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, then type "0RD983". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. For most vehicles, this repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. 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 Zone Service Office. Service Procedure 1. For Neon R/T vehicles equipped with a 2.0L High Output engine: Raise the vehicle on an appropriate hoist. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement > Page 3631 2. Disconnect the brake booster vacuum hose from the intake manifold nipple (Figure 1). NOTE: On Neon R/T vehicles, the intake manifold nipple is located on the rear of the manifold between the # 2 and # 3 cylinder runners. 3. For Neon R/T vehicles equipped with a 2.0L High Output engine: Lower the vehicle. 4. Disconnect the brake booster vacuum hose from the check valve on the brake booster (Figure 2). Do not remove the check valve from the brake booster. IMPORTANT: For Neon R/T vehicles equipped with a 2.0L High Output engine, disconnect the brake booster hose from the inline hose connector located near the brake booster. Do NOT disconnect the vacuum hose elbow from the brake booster check valve. 5. Remove and discard the brake booster vacuum hose. 6. Route the new vacuum hose in the same location as the original hose and then secure the hose with the clips on the left side of the valve cover. 7. Connect the brake booster vacuum hose to the check valve on the brake booster (Figure 2) or to the inline hose connector (Neon R/T vehicles). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 983 > Jun > 01 > Recall - Brake Booster Hose Replacement > Page 3632 8. Connect the brake booster vacuum hose to the intake manifold nipple (Figure 1). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3633 Vacuum Brake Booster: Specifications Make / Type Bosch/ Vacuum Diaphram Size 205 mm Diaphram Type Tandem Mounting Studs 300 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3634 Vacuum Brake Booster: Description and Operation For the Description and Operation of this Component Refer to Brakes, Description and Operation, System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3635 Vacuum Brake Booster: Testing and Inspection For Testing and Inspection Procedures on this Component refer to Brakes, Testing and Inspection, Procedures. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3636 Vacuum Brake Booster: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, 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 power brake booster. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3637 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3638 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 NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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. 2. Under the instrument panel, install the four power brake booster mounting nuts. Tighten the nuts to a torque of 34 Nm (300 inch 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 Antilock Brake System (ABS), install the Integrated Control Unit (ICU) mounting bracket on the frame rail using its three bolts. Tighten the nuts to a torque of 23 Nm (200 inch lbs.). 8. If the vehicle is equipped with ABS, reinstall the ICU. 9. Install the master cylinder. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations Controller Antilock Brake: Locations Fig.1 Integrated Control Unit (ICU) HCU Location The CAB is mounted to the bottom of the HCU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 3643 Controller Antilock Brake: Diagrams Controller Antilock Brake Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 3644 Controller Antilock Brake: Description and Operation Fig.1 Integrated Control Unit (ICU) CONTROLLER ANTILOCK BRAKE The controller antilock brake (CAB) is a microprocessor-based device which monitors the ABS system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: monitor the antilock brake system for proper operation. - detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - control fluid modulation to the wheel brakes while the system is in an ABS mode or the traction control system is activated. - store diagnostic information. - provide communication to the DRBIII scan tool while in diagnostic mode. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will send a message to the Mechanical Instrument Cluster (MIC) instructing it to turn ON the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning lamp is turned ON and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. These DTC's will remain in the CAB memory even after the ignition has been turned OFF. The DTC's can be read and cleared from the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles of vehicle operation. Controller Antilock Brake Inputs Wheel Speed sensors (four) - Brake Lamp switch - Ignition Switch - System Relay Voltage - Ground - Traction Control Lamp Actuation - Diagnostic Communication (PCI) Controller Antilock Brake Outputs Amber ABS warning indicator lamp actuation (through MIC) - Red BRAKE warning indicator lamp actuation (through MIC) - Traction control lamp - Diagnostic communication. (PCI) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 3645 Controller Antilock Brake: Service and Repair REMOVAL To remove the CAB, the ICU must be removed from the vehicle and disassembled. INSTALLATION To install the CAB, it must be attached to the HCU, forming the ICU. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation For Description and Operation of this Component refer to Brakes, Description and Operation, System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 3650 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 Service Precautions. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensor Head Mounting Bolt 105 in.lb Front Tone Wheel Clearance Minimum 0.011 in Maximum 0.056 in Rear Tone Wheel Clearance Minimum 0.018 in Maximum 0.044 in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 3659 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 3660 Wheel Speed Sensor: Connector Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3661 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Front Wheel Speed Sensor Connector (Sensor Side) Left Rear Wheel Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3662 Left Rear Wheel Speed Sensor Connector (Sensor Side) Right Front Wheel Speed Sensor Right Front Wheel Speed Sensor Connector (Sensor Side) Right Rear Wheel Speed Sensor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3663 Right Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3664 Wheel Speed Sensor: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component, Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Service Precautions. 1. Raise the vehicle. 2. Disconnect the Wheel Speed Sensor (WSS) 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. Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. 4. Remove the bolt mounting the WSS 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. 5. Carefully, remove the sensor head from the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3667 6. Remove the screw securing the WSS to the rear of the strut. Remove the WSS. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 (WSS) to the strut using the its mounting screw. 2. Install the WSS 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 WSS 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. Lower the vehicle. 6. Road test vehicle to ensure proper operation of the base brakes and Antilock Brake System (ABS). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3668 Wheel Speed Sensor: Service and Repair Rear REMOVAL NOTE: Before proceeding with this procedure, Refer to Service Precautions. 1. Raise the vehicle. 2. Disconnect the Wheel Speed Sensor (WSS) cable connector from the vehicle wiring harness. Remove the clip attaching WSS cable connector to the vehicle's body. 3. Remove the WSS 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 WSS cable routing bracket to rear strut. CAUTION: When removing a WSS 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 WSS to the rear disc brake adapter, then carefully remove the sensor head from the rear disc brake adapter and Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3669 vehicle. INSTALLATION NOTE: Before proceeding with this procedure, Refer to Service Precautions. 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 (WSS) head into the disc brake adapter. 2. Install the WSS mounting bolt. Tighten the mounting bolt to a torque of 12 Nm (105 inch lbs.). 3. Install the WSS cable routing bracket on the rear strut. 4. Install WSS cable into the routing clips on the rear brake hose and brake tube. 5. Connect the WSS cable connector into vehicle wiring harness. Install the clip attaching the WSS cable connector to vehicle's body. 6. Lower the vehicle. 7. Road test the vehicle to ensure proper operation of the base brakes and Antilock Brake System (ABS). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation DESCRIPTION The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 4). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 5), each switch being fastened by four plastic wing tabs. OPERATION CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch engaged and the transaxle in gear. The switch is open while the clutch pedal is at rest. When the clutch pedal is fully depressed, the pedal blade 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 3678 Clutch Switch: Testing and Inspection CLUTCH INTERLOCK/UPSTOP SWITCH The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 6). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 7), each switch being fastened by four plastic wing tabs. 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.) and for proper installation of the master cylinder push rod/bushing on the pedal pin. Also make sure the clutch pedal blade contacts and fully closes the switch. 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 with the interlock switch not depressed (clutch pedal at rest). There should be Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 3679 no continuity between the terminals (open circuit). 5. Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm. (0.050 inch). The ohmmeter should show continuity (0 ohms). 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. 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 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. CLUTCH INTERLOCK/UPSTOP SWITCH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 3680 Clutch Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 8). 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. 9). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 3681 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 10). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 10). 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. 10). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 11) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 3682 1. Install switches into the pedal bracket assembly as shown in (Fig. 11). Route harness as was prior to removal. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 34 Nm (25 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. 9). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 6. Connect clutch master cylinder pushrod. Loosen adjustment screw (Fig. 12) and gently lift clutch pedal upwards until the clutch pedal fully depresses the the upstop switch. Torque adjustment screw to 8 Nm (70 inch lbs.). 7. Connect interlock/upstop and stop lamp switch connectors. 8. Install left lower instrument panel bezel (Fig. 8). 9. Connect battery negative cable. 10. Verify proper switch operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral 25 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 3691 Neutral Safety Switch: Locations Park/Neutral Switch The 31TH Park/Neutral Position Switch is located on the automatic transaxle housing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 3692 Park/Neutral Position Switch (ATX) 31TH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > 31TH Transmission Neutral Safety Switch: Description and Operation 31TH Transmission PARK/NEUTRAL POSITION SWITCH - PCM INPUT Park/Neutral Switch The 31TH park/neutral position switch is located on the automatic transaxle housing. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. The PCM delivers 8.5 volts to the center terminal of the Park/Neutral switch. When the gear shift lever is moved to either the Park or the Neutral position, the PCM receives a ground signal from the Park/Neutral switch. With the shift lever positioned in Drive or Reverse, the Park/Neutral switch contacts open, causing the signal to the PCM to go high. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > Page 3695 Neutral Safety Switch: Testing and Inspection PARK/NEUTRAL STARTING AND BACK-UP LAMP SWITCH 31TH TEST The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > Page 3696 Neutral Safety Switch: Service and Repair TEST The 31TH park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. REMOVAL 1. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3701 8w-10-3 The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3702 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3703 Power Distribution Center Engine Starter Motor Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3704 Starter Relay: Service Precautions WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3705 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3706 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Starter Relay Pinout Starter Relay Pinout Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is. connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the ON position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3707 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the transmission range sensor only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the transmission range sensor and repair. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3708 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Refer to the appropriate wiring information for the location of the proper battery cable wire harness diagrams. The wiring information also includes 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 3713 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 3714 Battery Cable: Service and Repair REMOVAL 1. Turn the ignition switch to the OFF position. 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. Refer to the procedure. 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. Refer to the procedure. 4. Connect the remote battery negative cable terminal. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation Fig.1 Inlet Air 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 3722 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the vehicle. Refer to the procedure. Fig.19 Battery Tray Removal 2. Remove two nuts to the rear and two bolts to the front of the battery tray (Fig. 19). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Mitsubishi 4794222AA Rated Sae Amps ............................................................................................. ........................................................................................................... 85 amps Minimum Amps .................................................................................................................................... ..................................................................... 75 amps Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 3728 Alternator: Mechanical Specifications Generator Mounting Bolt...................................................................................................................... ....................................................54 Nm (40 Ft. Lbs) Generator Pivot Bolt............................................................................................................................. ....................................................54 Nm (40 Ft. Lbs) Pivot Bracket Bolts............................................................................................................................... ....................................................54 Nm (40 Ft. Lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3729 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3730 Alternator: Diagrams Generator Generator Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3731 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. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3732 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 accessory 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3733 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations Voltage Regulator: Locations The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations > Page 3737 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 battery temperature or inlet air temperature sensor (refer to Battery Temperature Sensor or Inlet Air Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 325 mv or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 325 mv above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation DESCRIPTION The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 4). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 5), each switch being fastened by four plastic wing tabs. OPERATION CLUTCH INTERLOCK SWITCH The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch engaged and the transaxle in gear. The switch is open while the clutch pedal is at rest. When the clutch pedal is fully depressed, the pedal blade 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 3742 Clutch Switch: Testing and Inspection CLUTCH INTERLOCK/UPSTOP SWITCH The clutch interlock/upstop switch is an assembly consisting of two switches: an engine starter inhibit switch (interlock) and a clutch pedal upstop switch (Fig. 6). The switch assembly is located in the clutch/ brake pedal bracket assembly (Fig. 7), each switch being fastened by four plastic wing tabs. 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.) and for proper installation of the master cylinder push rod/bushing on the pedal pin. Also make sure the clutch pedal blade contacts and fully closes the switch. 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 with the interlock switch not depressed (clutch pedal at rest). There should be Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 3743 no continuity between the terminals (open circuit). 5. Fully depress the clutch pedal to close the switch. The switch button should compress at least 1.25 mm. (0.050 inch). The ohmmeter should show continuity (0 ohms). 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. 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 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. CLUTCH INTERLOCK/UPSTOP SWITCH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 3744 Clutch Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove left lower instrument panel bezel (Fig. 8). 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. 9). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 3745 6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 10). 7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 10). 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. 10). 10. Remove pedal pivot shaft and remove brake and clutch pedals. 11. Remove the interlock/upstop switch assembly (Fig. 11) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch. INSTALLATION 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 3746 1. Install switches into the pedal bracket assembly as shown in (Fig. 11). Route harness as was prior to removal. 2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 34 Nm (25 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. 9). CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced. 6. Connect clutch master cylinder pushrod. Loosen adjustment screw (Fig. 12) and gently lift clutch pedal upwards until the clutch pedal fully depresses the the upstop switch. Torque adjustment screw to 8 Nm (70 inch lbs.). 7. Connect interlock/upstop and stop lamp switch connectors. 8. Install left lower instrument panel bezel (Fig. 8). 9. Connect battery negative cable. 10. Verify proper switch operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch, Park/Neutral 25 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 3758 Neutral Safety Switch: Locations Park/Neutral Switch The 31TH Park/Neutral Position Switch is located on the automatic transaxle housing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 3759 Park/Neutral Position Switch (ATX) 31TH Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Description and Operation > 31TH Transmission Neutral Safety Switch: Description and Operation 31TH Transmission PARK/NEUTRAL POSITION SWITCH - PCM INPUT Park/Neutral Switch The 31TH park/neutral position switch is located on the automatic transaxle housing. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. The PCM delivers 8.5 volts to the center terminal of the Park/Neutral switch. When the gear shift lever is moved to either the Park or the Neutral position, the PCM receives a ground signal from the Park/Neutral switch. With the shift lever positioned in Drive or Reverse, the Park/Neutral switch contacts open, causing the signal to the PCM to go high. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Description and Operation > Page 3762 Neutral Safety Switch: Testing and Inspection PARK/NEUTRAL STARTING AND BACK-UP LAMP SWITCH 31TH TEST The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Description and Operation > Page 3763 Neutral Safety Switch: Service and Repair TEST The 31TH park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. REMOVAL 1. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Recalls for Starter Motor: > 00V416000 > Dec > 00 > Recall 00V416000: Starter Motor Defective Starter Motor: Recalls Recall 00V416000: Starter Motor Defective Starter assemblies were built with suspect plastic terminal blocks which could develop stress cracks subsequent to their installation onto the body of the starter. Separation of the terminal block from the starter body could potentially allow the un-fused positive terminal to come into contact with an adjacent surface, providing a path to ground. This condition could overheat the starter wiring, creating the potential for a vehicle fire. Dealers will replace the starter terminal block jumper harness. Owner notification is expected to begin during January 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Recalls for Starter Motor: > 964 > Dec > 00 > Recall - Starter Motor Terminal Block Replacement Starter Motor: Recalls Recall - Starter Motor Terminal Block Replacement December 2000 Dealer Service Instructions for: Safety Recall No. 964 -- Starter Terminal Block Models 2001 (PL) Dodge Neon R/T NOTE: This recall applies only to the above vehicles equipped with a 2.0L High Output engine ("F" in the 8th VIN Position) built through October 23, 2000 (MDH 102307). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The starter motor terminal block on about 15 of the above vehicles may crack. This may allow the positive battery cable to short circuit, which could cause an engine compartment fire. Repair The starter motor terminal block must be replaced. Parts Information Part Number Description CAA09640 Terminal Block Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough terminal blocks to service 100% of those vehicles. Service Procedure 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 throttle body idle air control (IAC) motor and throttle position sensor (TPS) electrical connectors. 3. Disconnect the IAC and TPS wiring harness from the air cleaner box. 4. Disconnect the inlet air temperature sensor electrical connector. 5. Disconnect the vapor purge line at the 90 elbow connector near the power distribution center. 6. Remove the Powertrain Control Module (PCN) wiring harness from the two clips on the air cleaner box. 7. Remove the two (2) air cleaner box fasteners. 8. Disconnect the air inlet hose from the intake manifold. 9. Remove the throttle cable and speed control cable (if equipped) from the clamp on the upper radiator hose. 10. Remove the air cleaner box assembly and set it aside. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Recalls for Starter Motor: > 964 > Dec > 00 > Recall - Starter Motor Terminal Block Replacement > Page 3776 11. Cover the intake manifold opening to prevent debris from falling into the manifold. 12. Disconnect the positive battery cable from the starter terminal block. 13. Disconnect the terminal block jumper wire from the starter solenoid. 14. Using medium force, tap the terminal block stud with a hammer to remove the block from the starter boss. 15. Install the new terminal block onto the starter boss. Lightly tap the terminal block with a small wooden block and a hammer until the terminal block is flush with the starter boss. IMPORTANT: Do NOT tap the stud to install the terminal block or damage to the terminal block will occur. 16. Connect the terminal block jumper wire to the starter solenoid. Tighten the nut to 90 in-lbs (10 Nm) IMPORTANT: Install the jumper wire with the terminal crimp toward the engine block. Make sure that the jumper wire is routed away from the intake manifold. 17. Connect the positive battery cable to the terminal block. Tighten the nut to 90 in-lbs (10 Nm) 18. Remove the covering from the intake manifold opening. 19 Place the air cleaner box into position and connect the air inlet hose to the intake manifold. Tighten the inlet hose clamp securely. 20. Secure the throttle cable and speed control cable (if equipped) to the upper radiator hose. 21. Install the air cleaner box fasteners. 22. Secure the PCM harness in the clips on the air cleaner box. 23. Connect the vapor purge line. 24. Connect the inlet air temperature sensor electrical connector. 25. Connect the throttle body IAC and TPS electrical connectors. Secure the harness to the air cleaner box with the push clip. 26. Connect the negative battery cable. 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 recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace starter terminal block 08-96-41-82 0.4 hours Add the cost of the part plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim recessing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Recalls for Starter Motor: > 964 > Dec > 00 > Recall - Starter Motor Terminal Block Replacement > Page 3777 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 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, then type "0RD954". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. 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 Fast Auburn Hills, Michigan 48325-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 00V416000 > Dec > 00 > Recall 00V416000: Starter Motor Defective Starter Motor: All Technical Service Bulletins Recall 00V416000: Starter Motor Defective Starter assemblies were built with suspect plastic terminal blocks which could develop stress cracks subsequent to their installation onto the body of the starter. Separation of the terminal block from the starter body could potentially allow the un-fused positive terminal to come into contact with an adjacent surface, providing a path to ground. This condition could overheat the starter wiring, creating the potential for a vehicle fire. Dealers will replace the starter terminal block jumper harness. Owner notification is expected to begin during January 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 964 > Dec > 00 > Recall - Starter Motor Terminal Block Replacement Starter Motor: All Technical Service Bulletins Recall - Starter Motor Terminal Block Replacement December 2000 Dealer Service Instructions for: Safety Recall No. 964 -- Starter Terminal Block Models 2001 (PL) Dodge Neon R/T NOTE: This recall applies only to the above vehicles equipped with a 2.0L High Output engine ("F" in the 8th VIN Position) built through October 23, 2000 (MDH 102307). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The starter motor terminal block on about 15 of the above vehicles may crack. This may allow the positive battery cable to short circuit, which could cause an engine compartment fire. Repair The starter motor terminal block must be replaced. Parts Information Part Number Description CAA09640 Terminal Block Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough terminal blocks to service 100% of those vehicles. Service Procedure 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 throttle body idle air control (IAC) motor and throttle position sensor (TPS) electrical connectors. 3. Disconnect the IAC and TPS wiring harness from the air cleaner box. 4. Disconnect the inlet air temperature sensor electrical connector. 5. Disconnect the vapor purge line at the 90 elbow connector near the power distribution center. 6. Remove the Powertrain Control Module (PCN) wiring harness from the two clips on the air cleaner box. 7. Remove the two (2) air cleaner box fasteners. 8. Disconnect the air inlet hose from the intake manifold. 9. Remove the throttle cable and speed control cable (if equipped) from the clamp on the upper radiator hose. 10. Remove the air cleaner box assembly and set it aside. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 964 > Dec > 00 > Recall - Starter Motor Terminal Block Replacement > Page 3787 11. Cover the intake manifold opening to prevent debris from falling into the manifold. 12. Disconnect the positive battery cable from the starter terminal block. 13. Disconnect the terminal block jumper wire from the starter solenoid. 14. Using medium force, tap the terminal block stud with a hammer to remove the block from the starter boss. 15. Install the new terminal block onto the starter boss. Lightly tap the terminal block with a small wooden block and a hammer until the terminal block is flush with the starter boss. IMPORTANT: Do NOT tap the stud to install the terminal block or damage to the terminal block will occur. 16. Connect the terminal block jumper wire to the starter solenoid. Tighten the nut to 90 in-lbs (10 Nm) IMPORTANT: Install the jumper wire with the terminal crimp toward the engine block. Make sure that the jumper wire is routed away from the intake manifold. 17. Connect the positive battery cable to the terminal block. Tighten the nut to 90 in-lbs (10 Nm) 18. Remove the covering from the intake manifold opening. 19 Place the air cleaner box into position and connect the air inlet hose to the intake manifold. Tighten the inlet hose clamp securely. 20. Secure the throttle cable and speed control cable (if equipped) to the upper radiator hose. 21. Install the air cleaner box fasteners. 22. Secure the PCM harness in the clips on the air cleaner box. 23. Connect the vapor purge line. 24. Connect the inlet air temperature sensor electrical connector. 25. Connect the throttle body IAC and TPS electrical connectors. Secure the harness to the air cleaner box with the push clip. 26. Connect the negative battery cable. 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 recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace starter terminal block 08-96-41-82 0.4 hours Add the cost of the part plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim recessing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 964 > Dec > 00 > Recall - Starter Motor Terminal Block Replacement > Page 3788 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 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, then type "0RD954". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. 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 Fast Auburn Hills, Michigan 48325-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 3791 Starter Motor: Mechanical Specifications 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 3792 Starter Motor: Locations Fig.11 Starter Location Fig.12 Starter Mounting/Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 3793 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 3794 Starter Motor: Description and Operation STARTER MOTOR 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. STARTER MOTOR - HIGH OUTPUT 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.9 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 9). Fig.10 Air Cleaner Box 2. Disconnect the inlet hose from intake manifold and reposition the air cleaner box (Fig. 10). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 3797 Fig.11 Starter Location 3. Starter location (Fig. 11). Fig.12 Starter Mounting/Location 4. Remove starter bolts (Fig. 12). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 3798 Fig.13 Starter Electrical Connection 5. Remove starter assembly (Fig. 13). 6. Disengage latch and remove solenoid connector from starter assembly. 7. Remove battery positive connector from starter assembly. It is not necessary to remove the alternator output lead from the connector. Fig.14 Starter 8. Remove starter from vehicle (Fig. 14). 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. 13). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 3799 Fig.8 Starter Mounting/location 4. Position the starter face into transmission housing. Start bottom mounting bolt and thread in until bolt is snug (Fig.8). 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. 10). Fig.7 Battery Negative Cable Remove/Install 8. Connect negative battery cable (Fig.7). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 3800 Starter Motor: Service and Repair Starter Motor Replacement REMOVAL Fig.7 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 7). 2. On High Output engine remove Intake Manifold 3. Raise vehicle on hoist. Fig.8 Starter Mounting/location 4. Remove starter bolts (Fig. 8). 5. Remove starter assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter Motor - High Output > Page 3801 6. Disengage latch and remove solenoid connector from starter assembly. 7. Remove battery positive connector from starter assembly. It is not necessary to remove the alternator output lead from the connector. 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. High output engine install the intake manifold. 9. Connect negative battery cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3805 8w-10-3 The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3806 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3807 Power Distribution Center Engine Starter Motor Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3808 Starter Relay: Service Precautions WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3809 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3810 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Starter Relay Pinout Starter Relay Pinout Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is. connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the ON position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3811 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the transmission range sensor only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the transmission range sensor and repair. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3812 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Battery Nut................................................................................................................. .........................................................................10 Nm Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 3816 Starter Solenoid: Locations The Starter Solenoid is mounted directly to the Starter Motor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 3817 Starter Solenoid: Service Precautions WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 3818 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 3819 Starter Solenoid: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. 1. Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to Battery Tests. 2. Perform Starter Solenoid test BEFORE performing the starter relay test. 3. Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. 4. Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. 5. Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. a. If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. b. If engine does not crank or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. c. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Inspect the ring gear teeth. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3832 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3839 Auxiliary Power Outlet: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3840 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3841 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations 8w-11-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3846 Circuit Breaker: Diagrams Fuse Block (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3847 Circuit Breakers (LHD) Fuse Block (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3848 Circuit Breakers (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center (PDC): Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 Power Distribution Center (PDC): Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 3873 Power Distribution Center (PDC): Description and Operation 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 twelve 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 3874 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. Fig.3 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 3). 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. Torque nut retaining positive battery cable at PDC to 96 - 141 Nm (85 130 in. lbs.). 9. Reconnect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 3879 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 3880 Fuse: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 3881 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 3882 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3883 Fuse: Diagrams Fuse Block (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3884 Fuses (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3885 Fuse Block (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3886 Fuses (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3887 Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3888 Fuses (PDC) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block Fuse: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 3891 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 3892 Fuse: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 3893 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 3894 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block Fuse Block: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 3899 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 3900 Fuse Block: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 3901 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 3902 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3909 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3910 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3911 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 Fuse Block: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 Fuse Block: Electrical Diagrams 8w-11-2 Schematics Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 8w-15-4 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 8w-15-5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 8w-15-6 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 8w-15-7 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 8w-15-8 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 8w-15-9 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 8w-15-10 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 8w-15-11 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 8w-15-12 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 8w-15-13 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 8w-15-14 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 3936 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 3939 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 3940 Fuse Block: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 3941 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 3942 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 3943 Fuse Block: Description and Operation 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 Hock 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 3944 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3950 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3951 Relay Box: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3952 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3953 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3956 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3957 Relay Box: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3958 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 3959 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 3964 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 3965 Relay Box: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 3966 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 3967 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 3970 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 3971 Relay Box: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 3972 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 3973 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Wiring Harness: Customer Interest Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 3982 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Wiring Harness: All Technical Service Bulletins Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 3988 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 Auxiliary Power Outlet: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations 8w-11-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4015 Circuit Breaker: Diagrams Fuse Block (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4016 Circuit Breakers (LHD) Fuse Block (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4017 Circuit Breakers (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center (PDC): Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Power Distribution Center (PDC): Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4042 Power Distribution Center (PDC): Description and Operation 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 twelve 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4043 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. Fig.3 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 3). 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. Torque nut retaining positive battery cable at PDC to 96 - 141 Nm (85 130 in. lbs.). 9. Reconnect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 4048 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 4049 Fuse: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 4050 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 4051 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4052 Fuse: Diagrams Fuse Block (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4053 Fuses (LHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4054 Fuse Block (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4055 Fuses (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4056 Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4057 Fuses (PDC) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block Fuse: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 4060 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 4061 Fuse: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 4062 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block > Page 4063 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block Fuse Block: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 4068 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 4069 Fuse Block: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 4070 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block > Page 4071 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Fuse Block: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 Fuse Block: Electrical Diagrams 8w-11-2 Schematics Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 8w-15-4 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 8w-15-5 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 8w-15-6 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 8w-15-7 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 8w-15-8 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 8w-15-9 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 8w-15-10 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 8w-15-11 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 8w-15-12 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 8w-15-13 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 8w-15-14 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4105 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block Fuse Block: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 4108 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 4109 Fuse Block: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 4110 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block > Page 4111 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4112 Fuse Block: Description and Operation 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 Hock 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4113 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4119 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4120 Relay Box: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4121 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4122 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4125 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4126 Relay Box: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4127 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4128 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block Relay Box: Locations Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4133 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4134 Relay Box: Locations Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4135 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block > Page 4136 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block Relay Box: Application and ID Fuse Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4139 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4140 Relay Box: Application and ID Power Distribution Center Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4141 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block > Page 4142 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Wiring Harness: Customer Interest Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 4151 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) Wiring Harness: All Technical Service Bulletins Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) NUMBER: 08-025-02 GROUP: Electrical DATE: Dec. 20, 2002 SUBJECT: Air Bag Light "ON"/Erroneous Diagnostic Trouble Code (DTC) "STORED ENERGY FAULT" NOTE: THE SYMPTOM/CONDITION ADDRESSED IN THIS BULLETIN HAS NO AFFECT ON AIRBAG OPERATION. OVERVIEW: This bulletin involves installing a jumper harness/diode at the Leak Detection Pump (LDP). MODELS: 2000 - 2002 PL Neon SYMPTOM/CONDITION: Vehicle sets DTC "STORED ENERGY FAULT" with the airbag light on. NOTE: THE ABOVE MENTIONED DTC CAN BE GENERATED IF THE IGNITION SWITCH IS CYCLED ON AND OFF WITHIN A TEN SECOND PERIOD. A VOLTAGE SPIKE FROM THE LEAK DETECTION PUMP COULD OCCUR DUE TO THE PUMP RUNNING CONCURRENTLY IN THE SYSTEM SELF CHECK MODE. VEHICLES EQUIPPED WITH LESS OPTIONS ARE MORE SUSCEPTIBLE DUE TO THE LOWER NUMBER OF MODULES AVAILABLE TO ABSORB THE VOLTAGE SPIKE. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTC's are present, 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. Raise and support vehicle on a suitable hoist. 3. Locate the Leak Detection Pump (LDP) on the right side of the fuel tank. Push the locking tab on electrical connector to unlock and remove connector. 4. Install jumper harness/diode, p/n 05102874AA, between the LDP and the chassis harness connector. 5. Tie-strap any excess harness to the chassis harness. 6. Erase DTC "STORED ENERGY FAULT" and verify this DTC is not present. 7. If DTC "STORED ENERGY FAULT" reoccurs, replace the Airbag Control Module (ACM). POLICY: Reimbursable within the provisions of the warranty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-025-02 > Dec > 02 > Electrical - Air Bag Light ON/DTC (STORED ENERGY FAULT) > Page 4157 TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications CURB HEIGHT SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS NOTE: All specifications are given in degrees. NOTE: All wheel alignments are to be set with the vehicle at curb height. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4162 Alignment: Description and Operation DESCRIPTION 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. 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. 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 0.0°, the cross camber would be +0.3°. CASTER Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4163 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4164 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4165 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. Lee 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 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4166 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection STANDARD PROCEDURE - 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 tees 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4169 Alignment: Service and Repair Wheel Alignment Wheel Alignment Setup 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 Adjustment Bolt Package Installation 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 undersized allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersized bolts provide approximately two degrees 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. 2. Remove the wheel and tire assembly at the strut requiring modification. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4170 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 114 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. Camber and Caster Adjustment 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. Front Toe Adjustment 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4171 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. Rear Toe Adjustment 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4172 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 (66 ft. lbs.). 4. Proceed to FRONT TOE to set the front toe. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4173 Alignment: Service and Repair Curb Height Measurement STANDARD PROCEDURE - CURB HEIGHT 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4179 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4180 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4181 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4182 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint Stud Pinch Bolt Nut 70 ft.lb Disc Brake Caliper Guide 192 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4187 Front Steering Knuckle: Description and Operation DESCRIPTION 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 bottom, and steering linkage on the trailing end. The steering knuckle also has two machined, drilled and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4188 Front Steering Knuckle: Testing and Inspection DIAGNOSIS AND TESTING 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4189 Front Steering Knuckle: Service and Repair REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4190 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4191 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 C/V 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 (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. 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4192 2. Using Remover, Special Tool 4150A, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4193 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4194 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4195 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 honoring when 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4196 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 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4197 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4198 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 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4199 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4205 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4206 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4207 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4208 Power Steering Fluid: Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4209 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4210 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. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the dipstick level should indicate FULL (optimum level is at the FULL line). Do not overfill the power steering system. In all power steering systems, use only Mopar Power Steering Fluid (MS-9933), or its equivalent. NOTE: Do not use any type of automatic transmission fluid in the power steering system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Mounting Screws 90 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 4214 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 4215 Power Steering Fluid Cooler: Service and Repair REMOVAL 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. 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. They are located behind the cooler. They can be accessed from above. 6. Open the routing clip 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 fluid hose far enough to clear the steel fitting on the power steering gear once the hose is installed. 2. Slide the hose (with cooler attached) onto the fitting on the steering gear, then align the tube on back of the cooler with the open routing clip on the right front of the power steering gear housing, and snap it into place. Close the clip. 3. Install the hose clamp on the power steering cooler fluid hose past the bead formed into the steel fitting and secure in place. 4. 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.). 5. Install the power steering fluid return hose on the power steering fluid cooler 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. 6. Lower the vehicle. 7. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. See: Power Steering Pump/Service and Repair 8. Check for leaks at all connections. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Reservoir: > 19-05-00 > Jul > 00 > Power Steering - Moan at Low Speed Power Steering Fluid Reservoir: Customer Interest Power Steering - Moan at Low Speed NUMBER: 19-05-00 GROUP: Steering DATE: July 14, 2000 SUBJECT: Low Speed Power Steering Moan OVERVIEW: This bulletin involves the replacement of the power steering reservoir cap. The new power steering reservoir cap has an internal pressure relief valve and a revised dipstick. MODELS: 2000 - 2001 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MAY 24, 2000 (MDH 0524XX). SYMPTOM/CONDITION: A moan type sound may be heard during low speed steering wheel inputs at low engine RPM (low speed turns or parking lot maneuvers). DIAGNOSIS: Drive the vehicle slowly through the parking lot and make slow speed turns, if the power steering moan is heard, perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: THE POWER STEERING CAP SHOULD ONLY BE REMOVED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. 1. Before opening the power steering system, wipe the reservoir filler cap free of dirt and debris. 2. Remove the cap and discard. 3. Install the new cap and use the new dipstick to check the fluid level. Check the fluid when it is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the dipstick level should be right at the FULL mark. Correct the fluid level as needed, do not overfill the power steering system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Reservoir: > 19-05-00 > Jul > 00 > Power Steering - Moan at Low Speed Power Steering Fluid Reservoir: All Technical Service Bulletins Power Steering - Moan at Low Speed NUMBER: 19-05-00 GROUP: Steering DATE: July 14, 2000 SUBJECT: Low Speed Power Steering Moan OVERVIEW: This bulletin involves the replacement of the power steering reservoir cap. The new power steering reservoir cap has an internal pressure relief valve and a revised dipstick. MODELS: 2000 - 2001 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO MAY 24, 2000 (MDH 0524XX). SYMPTOM/CONDITION: A moan type sound may be heard during low speed steering wheel inputs at low engine RPM (low speed turns or parking lot maneuvers). DIAGNOSIS: Drive the vehicle slowly through the parking lot and make slow speed turns, if the power steering moan is heard, perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: THE POWER STEERING CAP SHOULD ONLY BE REMOVED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. 1. Before opening the power steering system, wipe the reservoir filler cap free of dirt and debris. 2. Remove the cap and discard. 3. Install the new cap and use the new dipstick to check the fluid level. Check the fluid when it is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the dipstick level should be right at the FULL mark. Correct the fluid level as needed, do not overfill the power steering system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > Page 4229 Power Steering Fluid Reservoir: Description and Operation DESCRIPTION The power steering fluid reservoir is mounted on the power steering pump using 3 bolts. It stores fluid for the power steering system. The power steering fluid reservoir is considered an integral part of the power steering pump and is not serviced separately. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Tube Nuts 25 ft.lb Hose Routing Clip Bolt 105 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4233 Power Steering Line/Hose: Description and Operation HOSES - DESCRIPTION The power steering fluid hoses connect the components of the power steering system. They transfer fluid from one component to the next. The power steering fluid pressure hose is a high pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting with an O-ring is used at each end to connect it to either the power steering pump or the gear. The power steering fluid return hose is a special rubber hose that connects the power steering gear or the power steering fluid cooler on some models, back to the fluid reservoir mounted on the power steering pump. The power steering gear has a steel fitting attached to its outlet port that the return hose is pushed onto. On vehicles equipped with a power steering fluid cooler, the return hose attaches to the cooler outlet tube instead of the steering gear steel fitting. The hose is secured to either component using a standard adjustable clamp. The other end of the power steering fluid return hose attaches to the power steering fluid reservoir on the power steering pump using a standard adjustable clamp. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL - POWER STEERING FLUID PRESSURE HOSE 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. 3. Back out the tube nut securing the power steering fluid pressure hose to the gear. 4. Open the routing clips on the right side of the power steering gear and remove the power steering fluid pressure hose tube from the routing clips. At the same time, remove the pressure hose tube from the gear. 5. Lower the vehicle. 6. Remove the bolt securing the hose routing clip in place on the right engine motor mount. Remove the power steering fluid pressure hose from 7. Back out the tube nut securing the power steering fluid pressure hose to the power steering pump and remove the hose from the pump. 8. Remove the power steering pressure hose from the engine compartment. INSTALLATION - POWER STEERING FLUID PRESSURE HOSE 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 back of 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 power steering fluid. 3. Attach the power steering fluid pressure hose to the outlet fitting on the bottom of the power steering pump. Tighten the pressure hose tube nut to a torque of 34 Nm (25 ft. lbs.). 4. Install the power steering fluid pressure hose in the routing clip and attach the clip to the right engine mount. Tighten the hose routing clip bolt 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 gear port. Replace the used O-ring with new. Lubricate the O-ring with power steering fluid. 7. Attach the power steering fluid pressure hose to the port on the power steering gear. Start the tube nut threads into the gear, but do not tighten it at this time. 8. Open the routing clips on the right side of the power steering gear and install the power steering fluid pressure hose into the routing clips. Close the clips. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 4236 9. Tighten the pressure hose tube nut at the gear to a torque of 34 Nm (25 ft. lbs.). 10. Lower the vehicle. 11. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. See: Power Steering Pump/Service and Repair 12. Check for leaks at all hose connections. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 4237 Power Steering Line/Hose: Service and Repair Hose - Return REMOVAL- POWER STEERING FLUID RETURN HOSE 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise the vehicle. 3. Remove the hose clamp securing the return hose to the cooler. Slide the hose off the end of the cooler tube. 4. Lower the vehicle. 5. Remove the bolt securing the hose routing clip in place on the right engine mount. Remove the power steering fluid return hose from the routing clip. 6. Remove the hose clamp securing the return hose to the power steering fluid reservoir. Slide the hose off the end of the reservoir fitting. 7. Remove the power steering return hose from the engine compartment. INSTALLATION - POWER STEERING FLUID RETURN HOSE 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 on the power steering fluid reservoir, then route the rest of the hose along the right side of the engine. Guide the gear end of the hose down behind the back of 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 power steering fluid return hose in the hose routing clip and attach the clip to the right engine mount. Tighten the hose routing clip bolt 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 gear port fitting or power steering fluid cooler port. 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. See: Power Steering Pump/Service and Repair 11. Check for leaks at all hose connections. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4242 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4243 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4244 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Pressure Hose Tube Nut 25 ft.lb Pressure Fitting 65 ft.lb Front Mounting Bolts 250 in.lb Rear Mounting Bolts 250 in.lb Rear Support Bracket to Engine Bolts 40 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4247 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4248 Power Steering Pump: Description and Operation DESCRIPTION The hydraulic pressure for operation of the power steering gear is provided by a belt driven power steering pump manufactured by TTA. The constant flow rate and displacement vane-type power steering pump is located on the front corner of the engine. In the event of a power steering pump drive belt failure, manual steering control of the vehicle can still be maintained. However, under these conditions, steering effort will be significantly increased. 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. OPERATION Hydraulic pressure is provided for operation of the power steering gear by the belt driven, constant displacement, vane type power steering pump. The power steering pump is connected to the steering gear by a power steering fluid pressure hose and return hose. Rectangular pumping vanes in the shaft driven rotor move power steering fluid from the intake to the cam ring pressure cavities of the power steering pump. As the rotor begins to turn, centrifugal force throws the vanes against the inside surface of the cam ring to pickup residual oil. This oil is then forced into the high pressure area. As more oil is picked up by the vanes, the additional oil is forced into the cavities of the thrust plate through two crossover holes in the cam ring and pressure plate. The crossover holes empty into the high pressure area between the pressure plate and the housing end cover. As the high pressure area is filled, oil flows under the vanes in the rotor slots, forcing the vanes to follow the inside surface of the cam ring. As the vanes reach the restricted area of the cam ring, oil is forced out from between the vanes. When excess oil flow is generated during high-speed operation, a regulated amount of oil returns to the pump intake side through a flow control valve. The flow control valve reduces the power required to drive the pump and holds down temperature build-up. When steering conditions exceed maximum pressure requirements, such as when the wheels are turned against the stops, the pressure built up in the steering gear exerts pressure on the spring end of the flow control valve. The high pressure lifts the relief valve ball from its seat and allows oil to flow through a trigger orifice located in the outlet fitting. This reduces pressure on the spring end of the flow control valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the pump to a safe level. Under normal power steering pump operating conditions, pressure requirements of the pump are below maximum, causing the pressure relief valve to remain closed. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS. CAUTION: Use only Mopar Power Steering Fluid (MS-9933). Do not use automatic transmission fluid. Do not overfill. Wipe the filler cap clean, then check the fluid level. The dipstick should indicate FULL (optimum level is at the FULL line) when the fluid is at normal temperature, approximately 21 - 27 °C (70 - 80 °F). 1. Fill the power steering fluid reservoir to the proper level and 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 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 and remove the hose from the pump. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4251 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. 9. Remove the power steering pump with reservoir from the engine. 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. Tighten 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.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4252 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. Perform the POWER STEERING PUMP INITIAL OPERATION procedure. See: Initial Operation 11. Check for leaks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4253 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL- 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. INSTALLATION - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4254 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications switch 70 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4259 Power Steering Pressure Switch: Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4260 Power Steering Pressure Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4261 Power Steering Pressure 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4262 Power Steering Pressure Switch: Service and Repair REMOVAL 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. Use only Mopar Power Steering Fluid, or equivalent. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 4267 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4276 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4277 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4278 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4279 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4285 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4286 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4287 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4288 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4297 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4298 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4299 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4300 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4306 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4307 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4308 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4309 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Mounting Bolts 45 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4313 Steering Gear: Description and Operation DESCRIPTION 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 and 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 and 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4314 Steering Gear: Service and Repair REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4315 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 MB991113. 7. Remove the tie rod heat shield. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4316 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4317 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4318 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4319 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. INSTALLATION 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. 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.). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4320 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, 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. See: Power Steering/Power Steering Pump/Service and Repair 31. Check for fluid leaks. 32. Adjust the front toe setting on the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4329 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4330 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4331 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4332 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4338 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4339 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4340 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4341 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4350 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4351 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4352 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4353 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4359 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4360 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4361 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4362 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Retaining Screw 40 ft.lb Airbag Mounting Screw 90 in.lb Speed Control Switch Screw 20 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 4366 Steering Wheel: Service Precautions WARNINGS AND CAUTIONS WARNING: BEFORE BEGINNING ANY SERVICE PROCEDURES THAT INVOLVES REMOVING THE AIR BAG, REMOVE AND ISOLATE THE NEGATIVE (-) BATTERY CABLE (GROUND) FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR BAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIR BAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIR BAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIR BAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS. BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIR BAG, REFER TO RESTRAINT SYSTEMS. WARNING: WHEN HANDLING AN UNDEPLOYED AIR BAG MODULE DURING SERVICING OF THE STEERING COLUMN, THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED: AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON THE BACK OF THE AIR BAG MODULE. - WHEN CARRYING A LIVE MODULE, THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF THE MODULE SHOULD ACCIDENTLY DEPLOY. - IF THE AIR BAG MODULE IS PLACED ON A BENCH OR OTHER SURFACE, THE PLASTIC COVER SHOULD BE FACE-UP TO MINIMIZE MOVEMENT, IN CASE OF ACCIDENTAL DEPLOYMENT. CAUTION: Safety goggles should be worn at all times when working on steering columns. CAUTION: Disconnect negative (ground) cable from the bakery, before servicing any column component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 4367 Steering Wheel: Service and Repair STEERING WHEEL REMOVAL WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. 1. Adjust the steering wheel so that the tires are in the straight ahead position. Then: a. Rotate the steering wheel half turn (180°) to the right (clockwise). b. Lock column with the ignition cylinder lock. 2. Disconnect and isolate the battery negative cable. 3. Remove the speed control switches and disconnect their wire connectors or covers. 4. Remove the Driver Airbag attaching bolts from the back of steering wheel. 5. Lift airbag and disconnect the airbag and horn wire connectors. 6. Remove steering wheel retaining screw. 7. Remove the steering wheel with a steering wheel puller. While removing the steering wheel take care to feed the wires gently through the holes in Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 4368 the steering wheel. 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. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 1 MINUTE BEFORE REMOVING ANY AIRBAG COMPONENTS. 1. Confirm that: a. The steering wheel position is a half turn (180°) to the right (clockwise). b. The column is locked with the ignition cylinder lock. c. Check that the turn signal stalk is in the neutral position. 2. Install the steering wheel ensuring the flats on hub align with the clock spring. Pull the horn lead, airbag and speed control leads through the larger slot. Ensure leads do not get pinched under the steering wheel. 3. Install the steering wheel retaining screw, and tighten it to 54.2 Nm (40 ft. lbs.) torque. 4. 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. 5. Connect the horn wire. 6. Install two bolts and tighten to 10 to 11 Nm (90 to 100 inch lbs.) torque. 7. 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 inch lbs.) torque. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO RESTRAINT SYSTEMS. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Steering Knuckle Nuts 40 ft.lb Tie Rod Jam Nut 55 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4373 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4374 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball Joint Wear Limit: If any movement of the Grease Fitting is detected, replacement of the Ball Joint is necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 4379 Ball Joint: Testing and Inspection DIAGNOSIS AND TESTING 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications Front Pivot Bolt 120 ft.lb Rear Pivot bolt 150 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Front Control Arm: Description and Operation Front LOWER CONTROL ARM-FRONT SUSPENSION DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Front > Page 4385 There is one lower control arm on each side of the vehicle. Each lower control arm is a stamped steel unit using rubber isolated pivot bushings to isolate it from the front suspension crossmember and frame of the vehicle. The rear bushing can be serviced separately. The front of the lower control arm is bolted to the front crossmember using a bolt through the center of the rubber pivot bushing. The rear of the lower control arm is mounted to both the front crossmember and the frame rail of the vehicle using a thru-bolt. The thru-bolt goes through both the crossmember and rear lower control arm bushing, threading directly into the frame rail of the vehicle. The left and right lower control arms are interconnected through a linked rubber isolated stabilizer bar. The outboard end of each lower control arm connects to the steering knuckle using a ball joint. The lower control arm connects to the steering knuckle through a ball joint mounted at the outboard end of the arm. The ball joint is pressed into the lower control arm and has a non-tapered stud with a notch for steering knuckle pinch bolt clearance. The ball joint stud is clamped and locked to the steering knuckle lower leg using a pinch bolt. The ball joint is lubricated for life during the manufacturing process. Once lubricated for life, the grease fitting head is snapped off by the manufacturer. This is done to eliminate the possibility of lubrication later in the ball joints life thus damaging the non-vented ball joint seal boot. The ball joint used on this vehicle is replaceable and, if found defective, can be serviced as a separate component of the lower control arm. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Front > Page 4386 Control Arm: Description and Operation Rear LATERAL ARMS-REAR DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Front > Page 4387 The lateral arms control the lateral movement of the rear suspension, specifically the knuckle. There are two lateral arms per side of the rear suspension. One arm is attached to the front end of the knuckle and the other is attached to the rear of the knuckle. The other end of each lateral arm attaches to the rear crossmember. Visually it appears that the left rear arm is mounted backwards in relation to the other arms. Although the left rear arm looks like it is same as the right rear arm, just reversed, it is not the same; the arms are not interchangeable. The front arms are interchangeable, but should be mounted with the side displaying the word "FORWARD" stamped into it toward the front of the vehicle. The trimmed outer edge of the arms will then be facing the rear of the vehicle. The lateral arms are made of stamped steel and have rubber isolator bushings at each end. The lateral arms are attached to the rear crossmember and knuckle using a unique bolt and nut assembly at each end. The lateral arm-to-rear crossmember attaching bolts are longer than the lateral arm-to-knuckle attaching bolts. Each lateral arm to knuckle attaching bolt and nut assembly uses two flat washers. Each lateral arm to rear crossmember attaching bolt uses one flat washer and one adjustment cam to provide a means for rear wheel alignment toe adjustment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection > Front Control Arm: Testing and Inspection Front FRONT SUSPENSION DIAGNOSIS AND TESTING - LOWER CONTROL ARM Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm stamping is serviced only as a complete component. The serviceable components of the lower control arm are: the ball joint, the ball joint grease seal and the lower control arm rear isolator bushing. Inspect both lower control arm isolator bushings fir severe deterioration and replace as required. Inspect the ball joint per the inspection procedure and replace as required. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection > Front > Page 4390 Control Arm: Testing and Inspection Rear REAR SUSPENSION DIAGNOSIS AND TESTING - LATERAL ARMS Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection > Front > Page 4391 Inspect each lateral arm. Look for signs of contact with an object that has caused damage to the lateral arm. If the lateral arm is bent or damaged, the lateral arm will require replacement. Do not attempt to repair or straighten a lateral arm. Inspect the lateral arm isolator bushings and their sleeves for signs of damage or deterioration. If damage or deterioration is present, replacement of the entire lateral arm will be required. The isolator bushings cannot be serviced separately from the lateral arms. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension Control Arm: Service and Repair Front Suspension Removal and Installation FRONT SUSPENSION REMOVAL - LOWER CONTROL ARM 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. 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. 4. Rotate the forward ends of the stabilizer bar downward. It may be necessary to loosen the stabilizer bar cushion retainer bolts a little to ease any turning resistance. 5. Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle. 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. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4394 6. 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. 7. If the right lower control arm is being serviced, perform the following: a. Remove the drive-belt splash shield fasteners. Remove the shield. b. 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. c. Remove the bolts mounting the engine torque strut in place, then remove the engine torque strut from the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4395 8. Remove the front pivot bolt attaching the lower control arm to the front suspension crossmember. Remove the rear pivot bolt attaching the lower control arm to the front suspension crossmember and frame rail. Remove the lower control arm from the crossmember. INSTALLATION - LOWER CONTROL ARM 1. Position the lower control arm into the crossmember. Install, but do not fully tighten, the rear pivot bolt attaching the lower control arm to the front suspension crossmember and frame rail. Install the front pivot bolt attaching the lower control arm to the front suspension crossmember. 2. Tighten the lower control arm rear pivot (and suspension crossmember) bolt to a torque of 203 Nm (150 ft. lbs.), then tighten the lower control arm front pivot bolt to a torque of 163 Nm (120 ft. lbs.). 3. Install the 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. 4. If the right lower control arm has been serviced, perform the following: a. Install the engine torque strut and mounting bolts. b. Install the washer on the end of the stud extending from the torque strut bolt. c. 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.). d. Install the drive-belt splash shield and fasteners. 5. Install a new ball joint stud pinch bolt and nut. Tighten the nut to a torque of 95 Nm (70 ft. lbs.). 6. Rotate the forward ends of the stabilizer bar into mounting position. 7. 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. 8. Lower the vehicle to ground level. 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. 9. 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.). 10. If previously loosened, tighten the stabilizer bar cushion retainer bolts to a torque of 28 Nm (250 inch lbs.). Disassembly and Assembly FRONT SUSPENSION 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4396 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4397 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 (BALL JOINT) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4398 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. 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. Install the lower control arm on the vehicle. NOTE: If the ball joint is equipped with a lubeable grease fitting, the joint will need to be lubricated once the lower control arm installation is complete. ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4399 1. Back the ball joint press C-4212F set screw outward so it does not extend out into the cup area. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4400 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4401 Control Arm: Service and Repair Rear Suspension REAR SUSPENSION REMOVAL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4402 Use the following procedure for removal of one or both lateral arms on one side of the vehicle's rear suspension. 1. Raise the vehicle. 2. Remove the rear tire and wheel assembly. 3. Remove the nut, bolt and washers attaching both lateral arms to the knuckle. 4. Remove nut, washer, bolt and wheel alignment cam attaching the lateral arms to the rear crossmember. 5. Remove the lateral arms from vehicle. INSTALLATION Use the following procedure for installation of one or both lateral arms on one side of the vehicle's rear suspension. NOTE: Both lateral arms when being installed, must be specifically positioned and orientated on the vehicle. The lateral arm that has the same size bushing sleeves on both ends must be mounted on the forward side of the crossmember and knuckle with the trimmed outer edge facing rearward. This front arm is also marked with the word "FORWARD." The side of the arm displaying this must face forward. The lateral arm with two different size bushing sleeves must be mounted on the rearward side of the crossmember and knuckle. Position the smaller bushing sleeve end at the knuckle and the larger bushing sleeve end at the rear crossmember (the larger bushing sleeve is necessary to accommodate the rear wheel alignment adjustment cam). If the rear arm is to be mounted on the right side, the trimmed outer edge must face rearward. If the rear arm is to be mounted on the left side, the trimmed outer edge must face forward. 1. Following the note above, place the forward lateral arm against the leading end of the knuckle, and then install the short lateral arm mounting bolt with a washer through the lateral arm and knuckle and out the trailing end of the knuckle. 2. Following the note above, install the small bushing sleeved end of the rear lateral arm onto the end of the bolt just installed through the knuckle. Install a washer and nut onto the end of the mounting bolt, but do not completely tighten the bolt at this time. 3. Install a wheel alignment adjustment cam on the long arm mounting bolt. 4. Hold the rear lateral arm up against the crossmember and install the long mounting bolt with the adjustment cam through the lateral arm bushing and rear crossmember. The bolt must be installed with the notch in the adjustment cam pointing straight up. 5. Position the forward lateral arm against the rear crossmember hole. Pass the long mounting bolt through the lateral arm bushing sleeve. 6. Install a washer and nut onto the end of lateral arm mounting bolt at the rear crossmember, but do not completely tighten the bolt at this time. NOTE: Once installed, each lateral arm should have the bow in its length facing downward. Both right side arms should have the trimmed outer edge facing toward the rear of the car. Left side arms should leave the trimmed outer edge facing each other. The mounting bolt at the knuckle should have the nut at the rear and the mounting bolt at the crossmember should have the nut at the front. 7. Install tire and wheel assembly on the vehicle. 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 136 Nm (100 ft. lbs.). 8. Lower the vehicle to the ground. 9. With suspension at curb height, tighten the lateral arm mounting bolt nut at the knuckle to 95 Nm (70 ft. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4403 10. With suspension at curb height, tighten the Lateral arm mounting bolt nut at the crossmember to 88 Nm (66 ft. lbs.). 11. Set the rear toe on the vehicle to specification as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 4408 Front Cross-Member: Service and Repair REMOVAL 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. Refer to Vehicle Lifting. 2. Remove both front tire and wheel assemblies from the vehicle. Fig. 10 3. Remove both stabilizer bar links from the vehicle (Fig. 10). 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. 10), and remove the stabilizer bar with cushions attached from the vehicle. Fig. 11 5. Remove the nut and pinch bolt clamping each ball joint stud to the steering knuckle (Fig. 11). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 4409 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 CN joint on the driveshaft. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. Fig. 12 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. 12). 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. 13 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 4410 9. Loosen and remove the four bolts attaching the power steering gear to the front suspension crossmember (Fig. 13). Remove the power steering gear from the front suspension crossmember. 10. Remove the drive-belt splash shield fasteners. Remove the shield. Fig. 14 11. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle (Fig. 14). Remove the washer behind the strut from the torque strut bolt. 12. Remove the bolts mounting the engine torque strut in place (Fig. 14), then remove the engine torque strut from the vehicle. NOTE: Before removing the front suspension cross-member from the vehicle, the location of the crossmember 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. 15 13. Using an awl, scribe a line (Fig. 15) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 4411 Fig. 16 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. 16). 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. 16). 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 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. 16). 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. 15). 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. 13). 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. 11). Tighten the nut to a torque of 95 N.m (70 ft.lbs.). 11. Install the engine torque strut and mounting bolts (Fig. 14). 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. 14). 13. Install the pencil strut to the right front corner of the crossmember and body of the vehicle (Fig. 14). Tighten the pencil strut nuts to a torque of 58 N.m (43 ft.lbs.). 14. Install the drive-belt splash shield and fasteners. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 4412 Fig. 17 NOTE: Before installing the stabilizer bar, make sure the bar is not upsidedown. 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. 17). 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. 10). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint Stud Pinch Bolt Nut 70 ft.lb Disc Brake Caliper Guide 192 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4416 Front Steering Knuckle: Description and Operation DESCRIPTION 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 bottom, and steering linkage on the trailing end. The steering knuckle also has two machined, drilled and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4417 Front Steering Knuckle: Testing and Inspection DIAGNOSIS AND TESTING 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4418 Front Steering Knuckle: Service and Repair REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4419 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4420 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 C/V 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 (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. 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4421 2. Using Remover, Special Tool 4150A, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4422 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4423 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4424 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 honoring when 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4425 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 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4426 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4427 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 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4428 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Description and Operation Radius Arm: Description and Operation TENSION STRUT DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Description and Operation > Page 4432 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Description and Operation > Page 4433 Radius Arm: Service and Repair TENSION STRUT REMOVAL 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 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 bushing is damaged or shows signs of deterioration, the tension strut must be replaced. The front bushing can not 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications Rear Knuckle: Specifications Brake Support Plate Mounting Bolts 55 ft.lb Disc Brake Adapter Mounting Bolt 55 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4437 Rear Knuckle: Description and Operation DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4438 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4439 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4440 Rear Knuckle: Service and Repair REMOVAL - KNUCKLE (REAR) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4441 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4442 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4443 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) 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 ADS 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications Stabilizer Bar: Specifications Front Suspension Cushion Retainer Bolts 250 in.lb Link Nut 275 in.lb Rear Suspension Cushion Retainer Bolts 300 in.lb Link Bolt Nut 200 in.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front Stabilizer Bar: Description and Operation Front DESCRIPTION-FRONT Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 4449 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 4450 Stabilizer Bar: Description and Operation Rear DESCRIPTION-REAR 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 4451 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Testing and Inspection > Front > Page 4454 Inspect for broken, cracked or distorted stabilizer bar cushions and retainers. Inspect for worn or damaged stabilizer bar links. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Testing and Inspection > Front > Page 4455 Stabilizer Bar: Testing and Inspection Rear DIAGNOSIS AND TESTING - STABILIZER BAR (REAR) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Testing and Inspection > Front > Page 4456 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front FRONT SUSPENSION REMOVAL 1. Raise the vehicle. 2. Remove both stabilizer bar links from the vehicle . Remove each link by holding 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 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 4459 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 4460 Stabilizer Bar: Service and Repair Rear REAR SUSPENSION REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 4461 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 4462 6. The cushions can be removed from the bar by utilizing the pre-formed slit in each cushion and peeling it off the bar. INSTALLATION 1. Install the cushions on the stabilizer bar by opening the slit in the cushion and wrapping the cushion around the bar. Then 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. a. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Tower Nuts 300 in.lb Steering Knuckle nuts 40 ft.lb Plus 90 degree turn Strut Shaft Nut 55 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 4468 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 4469 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 4470 The rear strut assembly includes the following components: Strut shaft retaining nut - Upper mount (rubber isolated) - Dust shield - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 4473 - 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 4474 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL - STRUT ASSEMBLY (FRONT) 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. Disassembly Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4477 DISASSEMBLY - STRUT ASSEMBLY (FRONT) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4478 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4479 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4480 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4481 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4482 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 INSTALLATION - STRUT ASSEMBLY (FRONT) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4483 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4484 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4485 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.). 7. Lower the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4486 Suspension Strut / Shock Absorber: Service and Repair Rear Removal REMOVAL - STRUT ASSEMBLY (REAR) 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4487 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4488 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4489 9. Open the deck lid. 10. If equipped, remove the carpet from the top of the strut tower. 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. 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-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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4490 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4491 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 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-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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4492 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4493 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4494 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 INSTALLATION - STRUT ASSEMBLY (REAR) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4495 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.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4496 7. Reinstall the stabilizer bar link: - 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. - Start the stabilizer bar link bolt with bushing from the top, down through the stabilizer bar, inner link bushings and sleeve, and strut link Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4497 mounting bracket. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Suspension Bearing Retainer Plate bolt 250 in.lb Driveshaft Hub Nut 180 ft.lb Wheel Mounting Nuts 100 ft.lb Rear Suspension Knuckle Retaining Nut 160 ft.lb Wheel Mounting Nuts 80 - 110 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4502 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB/BEARING The wheel bearing and hub are pressed into the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front > Page 4505 Wheel Bearing: Description and Operation Rear HUB/BEARING DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front > Page 4506 The hub and bearing is mounted on the rear knuckle's spindle. The hub and bearing adapts the tire and wheel assembly to the knuckle. It's bearing allows the tire and wheel assembly to rotate freely on the vehicle. All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. The only serviceable components of the hub and bearing are the wheel mounting studs. If a vehicle is equipped with antilock brakes, the tone wheels for the rear wheel speed sensors are pressed onto the hub. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4509 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING (REAR) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4510 The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. With the wheel, disc brake rotor or brake drum removed, rotate the hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub and bearing will require replacement. The bearing is not serviceable alone. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLY (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. 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. 2. Using Remover, Special Tool 4150A, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4513 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4514 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4515 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 honoring when 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4516 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 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4517 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4518 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4519 Wheel Bearing: Service and Repair Rear REMOVAL 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 any retainer clips from the wheel mounting studs, then pull the brake drum off the hub and bearing. 4. 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. 5. Remove the dust cap from the hub and bearing assembly. 6. Remove the retaining nut, then the hub and bearing from the knuckle's spindle. INSTALLATION 1. 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.). 2. Install the dust cap on the end of the hub and bearing. 3. 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.). 4. 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.). 5. Lower the vehicle to ground level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Driveshaft-to-Hub/Bearing 180 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > NHTSA01V039000 > Feb > 01 > Recall 01V039000: Label 'Recommended Tire Size' Tires: Recalls Recall 01V039000: Label 'Recommended Tire Size' Vehicle Description: Passenger vehicles built with 15" wheels, equipped with an R/T package. Certain vehicles were equipped with an incorrect tire placard. The vehicles were equipped with P195/50R16 tires but the tire placard indicated that the recommended tire sizes were P185/65R14 and P185/65R15. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." The label specifies the wrong recommended tire size. This could cause the owner to select incorrect replacement tires. Owners will be provided with a correct label and installation instructions. Owner notification is expected to begin during February 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory Technical Service Bulletin # 972 Date: 010201 Recall - Incorrect Tire Size Label Installed at Factory February 2001 Dealer Service Instructions for: Safety Recall No. 972 - Tire Label Models 2001 (PL) Dodge Neon R/T NOTE: This recall applies only to the above vehicles built through October 24, 2000 (MDH 1024XX). Safety Recall No. 961 also involves tire label replacement, but applies to 2001 model year Neon vehicles equipped with the Sport Appearance Package. To ensure prompt payment and accurate service completions, dealers must verify which recall the vehicle is involved in prior to submitting a claim. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 130 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label with out charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, P/N 04656997AA or P/N 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 4537 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles 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, then type "0RD972". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 4538 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label Technical Service Bulletin # 961 Date: 001201 Recall - Incorrect Tire Size Label December 2000 Safety Recall No. 961 - Tire Label Models 2001 (PL) Dodge Neon NOTE: This recall applies only to the above vehicles equipped with the Sport Appearance Package (Sales Code - ADV) built through October 24, 2000 (MDH 102419). IMPORTANT: Some of the vehicles within the above build period have already been repaired and, therefore, have been excluded from this recall IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 1,600 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label without charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, PN 04656997AA or PN 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 4543 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown: NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Functions 53 and VIP All involved vehicles 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, then type "0RD961". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 4544 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA01V039000 > Feb > 01 > Recall 01V039000: Label 'Recommended Tire Size' Tires: All Technical Service Bulletins Recall 01V039000: Label 'Recommended Tire Size' Vehicle Description: Passenger vehicles built with 15" wheels, equipped with an R/T package. Certain vehicles were equipped with an incorrect tire placard. The vehicles were equipped with P195/50R16 tires but the tire placard indicated that the recommended tire sizes were P185/65R14 and P185/65R15. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." The label specifies the wrong recommended tire size. This could cause the owner to select incorrect replacement tires. Owners will be provided with a correct label and installation instructions. Owner notification is expected to begin during February 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory Technical Service Bulletin # 972 Date: 010201 Recall - Incorrect Tire Size Label Installed at Factory February 2001 Dealer Service Instructions for: Safety Recall No. 972 - Tire Label Models 2001 (PL) Dodge Neon R/T NOTE: This recall applies only to the above vehicles built through October 24, 2000 (MDH 1024XX). Safety Recall No. 961 also involves tire label replacement, but applies to 2001 model year Neon vehicles equipped with the Sport Appearance Package. To ensure prompt payment and accurate service completions, dealers must verify which recall the vehicle is involved in prior to submitting a claim. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 130 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label with out charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, P/N 04656997AA or P/N 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 4554 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles 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, then type "0RD972". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 972 > Feb > 01 > Recall - Incorrect Tire Size Label Installed at Factory > Page 4555 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label Technical Service Bulletin # 961 Date: 001201 Recall - Incorrect Tire Size Label December 2000 Safety Recall No. 961 - Tire Label Models 2001 (PL) Dodge Neon NOTE: This recall applies only to the above vehicles equipped with the Sport Appearance Package (Sales Code - ADV) built through October 24, 2000 (MDH 102419). IMPORTANT: Some of the vehicles within the above build period have already been repaired and, therefore, have been excluded from this recall IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject An incorrect tire label may have been installed on about 1,600 of the above vehicles. The label specifies the wrong recommended tire size and, therefore, does not conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 110 - Tire Selection and Rims. Repair A new tire label must be installed over the vehicle's original label. New tire labels are being mailed directly to all vehicle owners known to DaimlerChrysler with the Owner Notification letter. The owners are requested to install the label themselves or, if preferred, to arrange for dealer installation of the owner-supplied label without charge. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough labels (included with the vehicle list) to service 100% of unsold vehicles according to our records. If an owner's label is lost, or if dealers require more labels for inventory vehicles, additional tire labels, PN 04656997AA or PN 04656997AB, may be ordered as needed. Service Procedure Apply the tire label as follows: 1. Open the driver's door and locate the original tire label as shown in Figure 1. 2. Clean the surface of the original tire label and apply the new label directly over it, covering the original label. Completion Reporting and Reimbursement Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 4560 Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown: NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not applicable. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Functions 53 and VIP All involved vehicles 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, then type "0RD961". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to install the supplied tire label over the original label on their vehicle. Any owner who prefers not to install the label is asked to schedule an appointment for the service with their dealer. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form (not shown). The involved vehicle and recall 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 Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 961 > Dec > 00 > Recall - Incorrect Tire Size Label > Page 4561 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 4562 Tires: Description and Operation DESCRIPTION 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 proper tire rotation interval. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 4563 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 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 4564 - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Fig. 2 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 4567 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 4568 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 PROCEDURES 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 4569 Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure. Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION Daimler Chrysler Corporation advocates driving at safe speeds within posted speed limits. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 4572 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 4576 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 4577 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 should 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 4578 Wheels: Service and Repair CLEANING - ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Any of the "DO NOT USE" items listed below WILL damage chrome plated and painted aluminum wheels. DO NOT USE: any abrasive metal cleaner - any abrasive cleaning pad or brush - any cleaner that contains an acid (this will immediately react with and discolor the chromium surface) - chrome polish (unless it is buffed off immediately after application) - oven cleaner - a car wash that uses carbide-tipped wheel cleaning brushes Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Suspension Bearing Retainer Plate bolt 250 in.lb Driveshaft Hub Nut 180 ft.lb Wheel Mounting Nuts 100 ft.lb Rear Suspension Knuckle Retaining Nut 160 ft.lb Wheel Mounting Nuts 80 - 110 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4583 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB/BEARING The wheel bearing and hub are pressed into the steering knuckle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 4586 Wheel Bearing: Description and Operation Rear HUB/BEARING DESCRIPTION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 4587 The hub and bearing is mounted on the rear knuckle's spindle. The hub and bearing adapts the tire and wheel assembly to the knuckle. It's bearing allows the tire and wheel assembly to rotate freely on the vehicle. All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. The only serviceable components of the hub and bearing are the wheel mounting studs. If a vehicle is equipped with antilock brakes, the tone wheels for the rear wheel speed sensors are pressed onto the hub. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4590 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING (REAR) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4591 The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. With the wheel, disc brake rotor or brake drum removed, rotate the hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub and bearing will require replacement. The bearing is not serviceable alone. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weepage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLY (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. 1. Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. 2. Using Remover, Special Tool 4150A, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4594 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4595 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4596 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 honoring when 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4597 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 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 (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4598 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4599 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4600 Wheel Bearing: Service and Repair Rear REMOVAL 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 any retainer clips from the wheel mounting studs, then pull the brake drum off the hub and bearing. 4. 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. 5. Remove the dust cap from the hub and bearing assembly. 6. Remove the retaining nut, then the hub and bearing from the knuckle's spindle. INSTALLATION 1. 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.). 2. Install the dust cap on the end of the hub and bearing. 3. 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.). 4. 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.). 5. Lower the vehicle to ground level. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 22-002-01 > Mar > 01 > Wheel Covers - Rattles on Bumps Wheel Cover: Customer Interest Wheel Covers - Rattles on Bumps NUMBER: 22-002-01 GROUP: Wheels/Tires DATE: Mar. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-002-00, DATED OCTOBER 6, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Wheel Cover Rattle - 14" Steel Wheels OVERVIEW: This bulletin involves the replacement of all four wheelcovers with revised parts. MODELS: 2000 - 2001 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO DECEMBER 12, 2000 (MDH 1212XX) EQUIPPED WITH 14" STEEL WHEELS (SALES CODE W4U). SYMPTOM/CONDITION: Rattle sound coming from the wheel cover over bumps. DIAGNOSIS: Drive the vehicle over a bump and listen for the rattle sound. If the rattle is heard, remove the wheel covers and verify the sound is gone. If the noise is gone with the wheel covers removed, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Install the four wheel covers onto the vehicle and torque nuts to 25 in.lbs. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 22-002-01 > Mar > 01 > Wheel Covers Rattles on Bumps Wheel Cover: All Technical Service Bulletins Wheel Covers - Rattles on Bumps NUMBER: 22-002-01 GROUP: Wheels/Tires DATE: Mar. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-002-00, DATED OCTOBER 6, 2000 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Wheel Cover Rattle - 14" Steel Wheels OVERVIEW: This bulletin involves the replacement of all four wheelcovers with revised parts. MODELS: 2000 - 2001 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO DECEMBER 12, 2000 (MDH 1212XX) EQUIPPED WITH 14" STEEL WHEELS (SALES CODE W4U). SYMPTOM/CONDITION: Rattle sound coming from the wheel cover over bumps. DIAGNOSIS: Drive the vehicle over a bump and listen for the rattle sound. If the rattle is heard, remove the wheel covers and verify the sound is gone. If the noise is gone with the wheel covers removed, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Install the four wheel covers onto the vehicle and torque nuts to 25 in.lbs. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Page 4614 Wheel Cover: Description and Operation WHEEL COVER DESCRIPTION This vehicle uses a bolt-on type wheel cover on models with steel wheels. The wheel cover is attached to the wheel using the 5 plastic nuts located in the wheel cover. The nuts in the wheel cover thread onto a special externally threaded wheel nut to retain the wheel cover to the wheel. Each wheel cover retaining nut is retained in the wheel cover and will stay on the wheel cover once it is unthreaded from the wheel nut. If required, the retaining nut can be removed from the wheel cover and replaced as a separate part of the wheel cover. The bolt-on wheel cover cannot be removed from the wheel until all 5 wheel cover retaining nuts are unthreaded from the wheel mounting nuts. At that time the wheel cover can easily be removed from the wheel by hand. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover Wheel Cover: Service and Repair Wheel Cover REMOVAL - WHEEL COVER NOTE: When unthreading the wheel cover retaining nuts from the wheel nuts, it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the wheel cover retaining nuts. 1. Unthread the 5 nuts attaching the wheel cover to the wheel nuts. 2. Grasp the wheel cover and pull straight outward from the wheel. This will remove the wheel cover from the wheel. INSTALLATION - WHEEL COVER 1. Align the valve notch in the wheel cover with the valve stem on the wheel. Align the wheel cover retaining nuts with the externally threaded wheel nuts. 2. By hand, start to thread all 5 of the wheel cover retaining nuts onto the externally-threaded wheel nuts. NOTE: When tightening the wheel cover retaining nuts it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the wheel cover retaining nuts. NOTE: To avoid rattling of the wheel cover, be sure all five retaining nuts are correctly tightened using the procedure described in the following step. 3. Progressively tighten each of the wheel cover retaining nuts following the pattern shown in the figure. Repeat the tightening sequence at least one more time. If a retaining nut "jumps a thread (slips), which is an override feature of the retaining nut, retighten all the nuts again following the proper tightening sequence to a point just prior to the thread slip occurring. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover > Page 4617 Wheel Cover: Service and Repair Wheel Cover Retaining Nut REMOVAL - WHEEL COVER RETAINING NUT 1. Remove the wheel cover from the wheel. NOTE: The retaining nut flange cannot be forced past the large retaining tab. When removing the retaining nut from wheel cover, the flange on the nut must instead be forced past the 2 small retaining tabs. 2. From the back side of the wheel cover, push outward and tilt the retaining nut sideways forcing the flange on the retaining nut past the 2 small retaining tabs in the retaining nut hole of the wheel cover, then remove the retaining nut from the wheel cover by pushing or pulling it from the hole in the wheel cover. INSTALLATION - WHEEL COVER RETAINING NUT 1. Install the retaining nut into the hole of wheel cover with the retaining nut flange positioned under the large retaining tab first, then push the nut flange past the small tabs snapping the nut into place. 2. Reinstall the wheel cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut, Driveshaft-to-Hub/Bearing 180 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 4626 Wheel Fastener: Specifications Wheel Mounting Lug Nut Hex Size 19mm Wheel Mounting Stud Size M12 x 1.5mm Wheel Mounting Lug nut 100 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4629 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4630 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 deepwell 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4631 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.17 A/C Vacuum Line Fig.18 Recirculation Air Door Vacuum Actuator The Neon 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Page 4637 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 instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 2. Disconnect vacuum line from actuator. Fig.20 Recirculation Door Actuator And Linkage 3. Disconnect actuator from recirculation door link. 4. Release tension on latch, and slide recirculation door actuator off housing. INSTALLATION The recirculation door actuator is a vacuum controlled actuator used to control movement of the recirculation door in air conditioned equipped vehicles. The instrument panel must be removed from the vehicle to gain access to the recirculation door actuator. 1. Position and secure the recirculation door actuator to the case. 2. Connect the actuator arm to the door link. 3. Connect the actuator vacuum line. 4. Install the Instrument Panel. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments Air Door Cable: Adjustments Fig.21 HVAC Housing Cables 1. Engage cable to actuator arm on temperature door and attach to housing. Fig.16 HVAC Control Head Cables 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. Fig.14 Instrument Panel Center Bezel And Knobs 1. Remove instrument panel center stack bezel. Fig.15 HVAC Center Air Duct And Control Head 2. Remove center air duct. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable Replacement > Page 4643 Fig.16 HVAC Control Head Cables 3. Remove heater-A/C control head and disconnect cable. 4. Disconnect cable at heater unit. 5. Remove cable from vehicle. INSTALLATION The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. 1. Position and connect the cable at the heater unit. 2. Connect the cable at the control head. 3. Install the Heater-A/C control 4. Install the instrument panel center stack bezel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable Replacement > Page 4644 Air Door Cable: Service and Repair Temperature Door Cable Replacement REMOVAL Fig.14 Instrument Panel Center Bezel And Knobs 1. Remove instrument panel center stack bezel. Fig.15 HVAC Center Air Duct And Control Head 2. Remove heater-A/C control head. 3. Remove center air duct. 4. Disconnect cable at control panel. Remove control from instrument panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable Replacement > Page 4645 Fig.21 HVAC Housing Cables 5. Disconnect cable at heater unit. 6. Remove cable from vehicle. INSTALLATION 1. Position the cable in the vehicle. 2. Connect the cable at the heater unit. 3. Connect the cable at the heater A/C control head. 4. Install the center air duct. 5. Install the heater A/C control head. 6. Install the instrument panel center stack bezel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Blower Motor Impeller > Component Information > Service and Repair Blower Motor Impeller: Service and Repair REMOVAL The blower motor is located on the bottom right side of the unit housing. The blower motor can removed from the vehicle without having to remove the unit housing assembly. With Air Conditioning 1. Remove right side scuff plate. 2. Pull back carpet. 3. Disconnect blower motor wiring connector. Fig.3 Blower Motor Retaining Screws 4. Remove blower motor retaining screws, and lower blower motor assembly from unit housing. Without Air Conditioning 1. Disconnect blower motor wiring connector. Fig.4 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Blower Motor Impeller > Component Information > Service and Repair > Page 4650 With Air Conditioning 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 right side scuff plate. Without Air Conditioning 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Fig.8 Blower Motor Resistor Block The blower motor resistor is located in the cowl, at the base of the windshield. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 4654 Blower Motor Resistor Block Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 4655 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 4656 Blower Motor Resistor: Description and Operation Fig.8 Blower Motor Resistor Block Fig.9 Blower Motor Resistors 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 4657 Blower Motor Resistor: Service and Repair REMOVAL CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed. 1. Remove windshield wipers. Refer to: "Wiper and Washer Systems : Wiper Arm : Service and Repair" See: Wiper and Washer Systems/Wiper Arm/Service and Repair 2. Remove cowl top screen. Fig.10 Blower Motor Resistors 3. Disconnect the resistor block wiring connector. 4. Remove/unsnap resistor block from vehicle. INSTALLATION CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed. Fig.11 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 4658 4. Install the windshield wipers. Refer to: "Wiper and Washer Systems : Wiper Arm : Service and Repair" See: Wiper and Washer Systems/Wiper Arm/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair 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. 7 3. Remove body vent from vehicle (Fig. 7). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... ............................ 0.41 - 0.79 mm (0.016 - 0.031 in.) Adjusted Air Gap ............................................................................................................................................................. 0.35 - 0.65 mm (0.014 - 0.026 in.) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4669 A/C Compressor Clutch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Do not mar the pulley frictional surface. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions > Page 4673 Compressor Clutch Coil: Service and Repair REMOVAL Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Fig.1 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.2 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions > Page 4674 Fig.3 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.4 Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service Precautions > Page 4675 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.5 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4679 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4680 Compressor Clutch Relay: Diagrams Power Distribution Center A/C Compressor Clutch Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4681 Power Distribution Center A/C Compressor Clutch Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condensor Lines ........................................................................................................................................................... 5 Nm (3.7 Ft.Lbs) (45 In.Lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 4685 Condenser HVAC: Locations The condenser is located in front of the engine radiator. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 4686 Condenser HVAC: Service Precautions WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE CONDENSER. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 4687 Condenser HVAC: Service and Repair REMOVAL The condenser is located in front of the engine radiator. It has no serviceable parts. If damaged or leaking, the condenser assembly must be replaced. WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE CONDENSER. 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. 2. Remove battery support strut. Fig.3 Condenser Refrigerant Lines 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 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams A/C - Heater Control Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4699 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4700 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4701 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4702 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4703 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4704 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4705 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4706 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4707 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4708 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4709 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4710 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4720 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4721 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4722 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4723 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4724 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4725 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4726 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4727 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4728 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4729 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4730 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-012-03 > Apr > 03 > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4731 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > Page 4732 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4733 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. For other probable causes, Refer to Cooling System; Testing and Inspection. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4734 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 inch lbs.). 4. Install the radiator upper hose. 5. Connect the coolant recovery/reserve system hose. 6. Fill the cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Component Information > Specifications Thermostat: Specifications Opening Temperature ......................................................................................................................... ............................................ 195 Degrees Farenheit Full Opening Temperature ............................................................................................................................................................. 216 Degrees Farenheit Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Component Information > Specifications > Page 4738 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Component Information > Specifications > Page 4739 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. For other probable causes, Refer to Cooling System; Testing and Inspection. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Component Information > Specifications > Page 4740 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 inch lbs.). 4. Install the radiator upper hose. 5. Connect the coolant recovery/reserve system hose. 6. Fill the cooling system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description and Operation Evaporator Drain Tube: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description and Operation > Page 4744 Evaporator Drain Tube: Service and Repair REMOVAL 1. Raise vehicle on a suitable lift. Fig.29 Condensate Water Drain Tube 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 clamp and install the tube over the nipple. 2. Lower the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator probe is located in the A/C housing and placed in the evaporator fins. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4748 Evaporator Temperature Sensor / Switch: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4749 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.12 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. Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2 °C to 7 °C (35 °F to 45 °F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4750 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 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.13 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 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 new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-001-01B > Aug > 01 > A/C System - Clunking/Honking Noise Expansion Valve: Customer Interest A/C System - Clunking/Honking Noise NUMBER: 24-001-01 REV. B GROUP: Heating and A/C DATE: Aug. 3, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-001-01 REV. A, DATED APRIL 20, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL SYMPTOM AND A REVISED PART. SUBJECT: A/C System Noise OVERVIEW: This bulletin involves replacement of the A/C expansion valve. MODELS: 2000 - 2001 (PL) Neon SYMPTOM/CONDITION: 1. Vehicles built prior to December 22, 2000 (MDH 1222XX); if the vehicle is shut off with the air conditioning compressor engaged and allowed to sit overnight, an audible clunk type sound may be heard from the engine compartment at initial engine start-up. This condition is most noticeable in moderate to warm ambient temperatures and is not detrimental to the operation of the compressor. 2. **All vehicles; "honk" sound coming from the expansion valve when the ambient temperature is around 27° C. (80.) and the humidity around 40% with the vehicle engine warmed up. Sound may be heard after the engine speed is raised to 3500-4000 RPM for one minute and allowed to return to idle. The "honk" noise will occur within 30 seconds.** **If either symptom can be duplicated or described by the owner, perform the Repair Procedure. ** PARTS REQUIRED: REPAIR PROCEDURE: Refer to the appropriate Neon Service Manual or the service information available in MDS2 for a/c expansion valve removal and installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-001-01B > Aug > 01 > A/C System - Clunking/Honking Noise > Page 4759 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise Expansion Valve: Customer Interest A/C - Poor Performance/Expansion Valve Noise NUMBER: 24-008-01 GROUP: Heating & A/C DATE: Jun. 22, 2001 SUBJECT: Poor A/C Performance/Expansion Valve Noise OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) with new software and reducing the amount of R134A refrigerant in the system to 765 grams (27 oz. or 1.69 lbs.). MODELS: 2001 (PL) Neon 2001 (P2) Neon (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE JUNE 11, 2001 (MDH O611XX). SYMPTOM/CONDITION: Some vehicles may exhibit one or both of the following symptoms: ^ Under high ambient conditions, typically above 38°C. (100° F.), the A/C compressor may cycle off and on repeatedly producing poor A/C performance immediately after a hot engine restart or during city driving. ^ Under similar ambient conditions listed above the A/C expansion valve may be noisy (hum sound). DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2085 OR HIGHER. REPAIR PROCEDURE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 4764 1. Evacuate and recharge the A/C system to 765 grams (27 oz. or 1.69 lbs.) of R134A refrigerant as described on page 24-4 of the 2001 Neon Service Manual (Publication No. 81-270-1025). 2. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool). 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 cover the label with the clear plastic overlay. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 4765 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-001-01B > Aug > 01 > A/C System - Clunking/Honking Noise Expansion Valve: All Technical Service Bulletins A/C System - Clunking/Honking Noise NUMBER: 24-001-01 REV. B GROUP: Heating and A/C DATE: Aug. 3, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-001-01 REV. A, DATED APRIL 20, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL SYMPTOM AND A REVISED PART. SUBJECT: A/C System Noise OVERVIEW: This bulletin involves replacement of the A/C expansion valve. MODELS: 2000 - 2001 (PL) Neon SYMPTOM/CONDITION: 1. Vehicles built prior to December 22, 2000 (MDH 1222XX); if the vehicle is shut off with the air conditioning compressor engaged and allowed to sit overnight, an audible clunk type sound may be heard from the engine compartment at initial engine start-up. This condition is most noticeable in moderate to warm ambient temperatures and is not detrimental to the operation of the compressor. 2. **All vehicles; "honk" sound coming from the expansion valve when the ambient temperature is around 27° C. (80.) and the humidity around 40% with the vehicle engine warmed up. Sound may be heard after the engine speed is raised to 3500-4000 RPM for one minute and allowed to return to idle. The "honk" noise will occur within 30 seconds.** **If either symptom can be duplicated or described by the owner, perform the Repair Procedure. ** PARTS REQUIRED: REPAIR PROCEDURE: Refer to the appropriate Neon Service Manual or the service information available in MDS2 for a/c expansion valve removal and installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-001-01B > Aug > 01 > A/C System - Clunking/Honking Noise > Page 4771 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise Expansion Valve: All Technical Service Bulletins A/C - Poor Performance/Expansion Valve Noise NUMBER: 24-008-01 GROUP: Heating & A/C DATE: Jun. 22, 2001 SUBJECT: Poor A/C Performance/Expansion Valve Noise OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) with new software and reducing the amount of R134A refrigerant in the system to 765 grams (27 oz. or 1.69 lbs.). MODELS: 2001 (PL) Neon 2001 (P2) Neon (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE JUNE 11, 2001 (MDH O611XX). SYMPTOM/CONDITION: Some vehicles may exhibit one or both of the following symptoms: ^ Under high ambient conditions, typically above 38°C. (100° F.), the A/C compressor may cycle off and on repeatedly producing poor A/C performance immediately after a hot engine restart or during city driving. ^ Under similar ambient conditions listed above the A/C expansion valve may be noisy (hum sound). DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2085 OR HIGHER. REPAIR PROCEDURE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 4776 1. Evacuate and recharge the A/C system to 765 grams (27 oz. or 1.69 lbs.) of R134A refrigerant as described on page 24-4 of the 2001 Neon Service Manual (Publication No. 81-270-1025). 2. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool). 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 cover the label with the clear plastic overlay. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-008-01 > Jun > 01 > A/C - Poor Performance/Expansion Valve Noise > Page 4777 FAILURE CODE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4778 Expansion Valve: Specifications Expansion Valve bolt .......................................................................................................................................................... 11 Nm (8.1 Ft.Lbs) (97 In.Lbs) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4779 Expansion Valve: Service Precautions WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO PERSONAL INJURY CAN RESULT. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4780 Expansion Valve: Testing and Inspection NOTE: Expansion valve tests should be performed after compressor tests. Liquid CO is required to test the expansion valve. It is available from most welding supply facilities. CO 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 ° 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. Fig.15 Expansion Valve And Low Pressure Cut-off Switch - Typical 2. Disconnect wire connector at low pressure cut-off 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 CO 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 to 241 kPa (15 to 35 psi). If not, replace expansion valve. 9. When expansion valve test is complete, test A/C overall performance. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4781 Expansion Valve: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 1. Recover and evacuate the refrigerant system. 2. Remove the wire connector from the low pressure cut-off switch. Fig.16 Expansion Valve - Typical 3. Remove the center bolt of refrigerant line plumbing sealing plate. 4. Carefully pull the refrigerant line-sealing plate assembly from the expansion valve towards front of vehicle. Do not scratch the expansion valve sealing surfaces with pilot tubes. 5. Cover the openings on A/C line-sealing plate assembly to prevent contamination. 6. Remove two screws securing the expansion valve to the evaporator sealing plate. 7. Carefully remove valve. INSTALLATION WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 1. Remove and replace the aluminum gasket on the evaporator sealing plate. 2. Carefully hold the expansion valve to the evaporator sealing plate so not to scratch the sealing surface. Install two screws and tighten to 11 ± 3 Nm (100 ± 30 in. lbs.). 3. Remove and replace the aluminum gasket on the refrigerant line- sealing plate assembly. 4. Carefully hold the refrigerant line-sealing plate assembly to the expansion valve. Install bolt and tighten to 23 ± 3 Nm (200 ± 30 in. lbs.). 5. Connect wires to low pressure cut-off switch. 6. Evacuate the refrigerant system. 7. Recharge the refrigerant system. 8. After expansion valve is installed, system is charged, and leaks have been checked, repeat A/C performance check. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions Heater Core: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 AIR-BAG 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement - RHD Heater Core: Service and Repair Heater Core Replacement - RHD REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 AIR-BAG 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. 1. Disconnect the negative battery cable. 2. Drain the cooling system. 3. Evacuate the refrigerant system. 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 Fig.17 Expansion Valve Position And Orientation 5. Remove the refrigerant line retaining bolt from the expansion valve. Remove the refrigerant lines from the expansion valve. 6. Disconnect the electrical connector from the bottom of the expansion valve. 7. Remove the expansion valve retaining bolts and remove the valve from the vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement - RHD > Page 4787 Fig.18 Heater Core Coolant Supply Lines 8. Remove the heater core coolant supply hoses from the heater core. 9. Working from inside the engine compartment, remove the A/C-Heater housing retaining fasteners from the bulkhead. 10. Remove the A/C-Heater housing drain tube. Remove the spring clip and pull the hose from the housing nipple. 11. Working from inside the vehicle, remove the defroster duct from the A/C-Heater housing and body attachment point. 12. Remove the A/C-Heater housing retaining bolts. 13. Disconnect the electrical connectors from the A/C-Heater housing. 14. Remove the A/C-Heater housing from the vehicle and place the assembly on a bench. 15. Remove the heater core cover from the housing assembly. 16. Remove the heater core coolant lines from the heater core. Fig.19 Heater A/C Housing Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement - RHD > Page 4788 17. Remove the screws necessary to disassemble the A/C-Heater housing assembly. 18. Remove the heater core from the A/C-Heater housing. INSTALLATION Fig.20 Heater A/C Housing 1. Install the heater core in the A/C-Heater housing. 2. Reassemble the A/C-Heater housing. 3. Install the housing in the vehicle and install the retaining bolts. Torque the bolts to 20 Nm (177 in. lbs.). 4. Connect the electrical connectors on the A/C- Heater housing. 5. Install the defroster duct on the A/C-Heater housing and secure at the body attachment point. 6. Install the A/C-Heater housing drain tube and retaining clip. 7. Install the A/C-Heater housing retaining fasteners. Torque the fasteners to 20 Nm (177 in. lbs.). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement - RHD > Page 4789 Fig.21 Heater Core Coolant Supply Lines 8. Install the heater core coolant supply hoses on the heater core. 9. Install the expansion valve, gasket and retaining bolts. Torque the bolts to 11 Nm (97 in. lbs.). Fig.22 Expansion Valve Position And Orientation 10. Connect the electrical connector on the bottom of the expansion valve. CAUTION: Be certain the refrigerant line sealing O-rings are well lubricated and free of tears. 11. Install the refrigerant lines and retaining bolt. Torque the bolt to 23 Nm (203 in. lbs.). 12. 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 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. 15. Fill the cooling system . 16. Connect the negative battery cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REMOVAL 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. 1. Drain engine cooling system. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Fig.23 Heater Hoses And Clamps 2. Using spring tension clamp pliers, remove clamps at end of heater hose to be removed. 3. Carefully rotate hose back and forth while pulling away from connector nipple. INSTALLATION 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. 1. Using spring tension clamp pliers, install the hose ends into position. 2. Refill the cooling system. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 4795 Heater Hose: Service and Repair Heater Return Hose Replacement REMOVAL 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. 1. Drain engine cooling system. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Fig.24 Heater Hoses And Clamps 2. Using spring tension clamp pliers, 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. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 4796 Heater Hose: Service and Repair Heater Tube Assembly Replacement REMOVAL 1. Disconnect negative battery cable. Disconnect positive battery cable. Remove battery. 2. Raise vehicle on hoist. 3. Drain cooling system . Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 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. 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. Refer to: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions High Pressure Safety Valve HVAC: Service Precautions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Page 4800 High Pressure Safety Valve HVAC: Service and Repair REMOVAL 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. 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 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. 1. Install a new O-ring. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 4804 Hose/Line HVAC: Locations Fig.4 A/C Compressor Lines The suction line is the large line that connects to the expansion valve and goes to the compressor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Fig.4 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 4807 Hose/Line HVAC: Description and Operation A/C Liquid Hose/Line Fig.4 A/C Compressor Lines 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 4808 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line Fig.4 A/C Compressor Lines 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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 A/C system. Fig.5 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 4811 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 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 WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 4812 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement 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.27 Expansion Valve Center Bolt 2. Remove retaining bolt at expansion valve. 3. Remove line at expansion valve. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 4813 Fig.28 A/C Compressor Suction Line 4. Remove line at 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement 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, if equipped. 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: "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.5 HVAC Vacuum Harness 9. Disconnect the vacuum harness at the power brake booster. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4818 Fig.6 HVAC Housing Defroster Duct 10. Unsnap and remove the defroster duct. Fig.7 Dash Panel Retaining Studs 11. Remove three retaining nuts located in the engine compartment, on the dash panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4819 Fig.6 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. 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: "Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 13. Evacuate the refrigerant system . 14. Recharge the refrigerant system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4820 Housing Assembly HVAC: Overhaul 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.9 HVAC Housing Air Distribution Foam Seals 1. Separate the air distribution outlet foam seals at the case parting line. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4821 Fig.10 HVAC Housing Evaporator Connection And Heater Core Tube Seals 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/evaporator out of the case. ASSEMBLY 1. Install the heater core/evaporator 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 right side of the engine compartment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations > Page 4825 Receiver Dryer: Service and Repair REMOVAL 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. 1. Evacuate and recover the refrigerant. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Refrigerant Before July 1 ..................................................................................................................................................... 765 g (27 oz or 1.69 lbs) R134a Refrigerant After July 1 ............................................................................................................ .......................................................... 851 g (1.88 lbs) See TSB # 24-23-99 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 4830 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 4831 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 4832 http://www.macsw.org/ Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Locations Refrigerant Filter: Locations The filter/drier is mounted in a rubber grommet on the right side of the engine compartment. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Locations > Page 4836 Refrigerant Filter: Service and Repair REMOVAL 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. 1. Evacuate and recover the refrigerant. 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 4841 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 4842 Refrigerant Oil: Service and Repair 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. The 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.6 High Pressure Cutout Switch Location The high pressure cut out switch is located on the rear of the compressor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4847 High Pressure Sensor / Switch: Service Precautions WARNING: - THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. - THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4848 High Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH Fig.6 High Pressure Cutout Switch Location 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4849 High Pressure Sensor / Switch: Service and Repair REMOVAL WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. 1. Recover refrigerant from A/C system. 2. Disconnect wiring connector at the switch. 3. Remove internal snap ring. 4. Pull switch out of compressor. INSTALLATION WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. 1. Clean any foreign matter from the switch mounting bore 2. Install the high pressure cutout switch with a new O-ring into the compressor. 3. Install the internal snap ring 4. Connect the wire harness to the switch. 5. Evacuate the refrigerant system. 6. Recharge the A/C system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.7 Expansion Valve And Low Pressure Cut-off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4853 Low Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH Fig.6 High Pressure Cutout Switch Location 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) A/C LOW PRESSURE SWITCH Fig.7 Expansion Valve And Low Pressure Cut-off Switch The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. The low pressure cut off switch is located on the expansion valve. The low pressure cut off switch turns OFF voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The low pressure cut Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4854 Low Pressure Sensor / Switch: Testing and Inspection The work area must not be below 21 °C (70 °F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kpa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4855 Low Pressure Sensor / Switch: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. 1. Recover A/C refrigerant. 2. Disconnect the wire connector at the cut off switch. Fig.7 Expansion Valve And Low Pressure Cut-off Switch 3. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. NOTE: Verify the O-ring condition on the replacement switch. 1. Using a sender unit socket, install the low pressure cutout switch into the expansion valve. 2. Connect the wire harness connector to the switch. 3. Evacuate the A/C refrigerant system. 4. Recharge the A/C system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4860 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4861 Compressor Clutch Relay: Diagrams Power Distribution Center A/C Compressor Clutch Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4862 Power Distribution Center A/C Compressor Clutch Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator probe is located in the A/C housing and placed in the evaporator fins. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4867 Evaporator Temperature Sensor / Switch: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4868 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.12 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. Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2 °C to 7 °C (35 °F to 45 °F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and retest outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4869 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 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.13 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 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 new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.6 High Pressure Cutout Switch Location The high pressure cut out switch is located on the rear of the compressor. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4874 High Pressure Sensor / Switch: Service Precautions WARNING: - THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. - THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4875 High Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH Fig.6 High Pressure Cutout Switch Location 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) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4876 High Pressure Sensor / Switch: Service and Repair REMOVAL WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. 1. Recover refrigerant from A/C system. 2. Disconnect wiring connector at the switch. 3. Remove internal snap ring. 4. Pull switch out of compressor. INSTALLATION WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE HIGH PRESSURE CUT OUT SWITCH. 1. Clean any foreign matter from the switch mounting bore 2. Install the high pressure cutout switch with a new O-ring into the compressor. 3. Install the internal snap ring 4. Connect the wire harness to the switch. 5. Evacuate the refrigerant system. 6. Recharge the A/C system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.7 Expansion Valve And Low Pressure Cut-off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4880 Low Pressure Sensor / Switch: Description and Operation A/C HIGH PRESSURE SWITCH Fig.6 High Pressure Cutout Switch Location 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) A/C LOW PRESSURE SWITCH Fig.7 Expansion Valve And Low Pressure Cut-off Switch The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. The low pressure cut off switch is located on the expansion valve. The low pressure cut off switch turns OFF voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The low pressure cut Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4881 Low Pressure Sensor / Switch: Testing and Inspection The work area must not be below 21 °C (70 °F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kpa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 4882 Low Pressure Sensor / Switch: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. 1. Recover A/C refrigerant. 2. Disconnect the wire connector at the cut off switch. Fig.7 Expansion Valve And Low Pressure Cut-off Switch 3. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO REFRIGERANT RECOVERY. NOTE: Verify the O-ring condition on the replacement switch. 1. Using a sender unit socket, install the low pressure cutout switch into the expansion valve. 2. Connect the wire harness connector to the switch. 3. Evacuate the A/C refrigerant system. 4. Recharge the A/C system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Fig.30 A/C Service Port Valves 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 4886 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 4887 Service Port HVAC: Description and Operation Fig.30 A/C Service Port Valves 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 4888 Service Port HVAC: Service and Repair Fig.30 A/C Service Port Valves 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 carefull to prevent any dirt/debris from entering the valve core opening or getting on the replacement valve core. INSTALLATION 1. When assembling the new valve core into the port, the core should be oiled with clean ND8 PAG compressor oil. CAUTION: A valve that is not fully seated can lead to damage to the valve during evacuation and charge. This can result in system refrigerant discharge while uncoupling the charge adapters. 2. Install valve core into port. 3. Evacuate the refrigerant system. 4. Recharge the refrigerant system. 5. Install the valve caps. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Testing and Inspection Vacuum Check Valve HVAC: Testing and Inspection Fig.19 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 very 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Testing and Inspection > Page 4892 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 4898 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 4903 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 4908 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Module (DAB) Air Bag: Locations Driver Airbag Module (DAB) Fig.11 Driver Airbag Location The driver airbag module is mounted directly to the steering wheel. Located under the airbag module trim cover are the horn switch, the folded airbag cushion, and the airbag cushion supporting components. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Module (DAB) > Page 4911 Air Bag: Locations Passenger Airbag Module (PAB) Fig.14 Passenger Airbag Location The passenger airbag is located behind the passenger airbag cover, between the glove box and instrument panel top cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Module (DAB) > Page 4912 Air Bag: Locations Seat Airbag Module Fig.18 Seat Airbag - Typical The left and right seat airbags are located in the outboard edge of the front seat backs. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 4913 Air Bag: Diagrams C208 (Right Seat Airbag) C208 (Right Seat Airbag) C209 (Left Seat Airbag) C209 (Left Seat Airbag) Driver Airbag Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 4914 Left Seat Airbag Passenger Airbag Right Seat Airbag Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Airbag Air Bag: Description and Operation Driver Airbag Fig.11 Driver Airbag Location DRIVER AIRBAG MODULE (DAB) The driver airbag module protective trim cover is the most visible part of the driver airbag system. The driver airbag module is mounted directly to the steering wheel. Located under the airbag module 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 module cover and the backer plate which is heat staked on to the driver airbag module cover. The driver airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag module trim cover and the horn switch are available for service replacement. The driver airbag module 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 module 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 module metal housing. Two stamped metal retainers then fit over the inflator mounting studs on the back of the airbag module 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. THE AIRBAG MODULE 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). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Airbag > Page 4917 Air Bag: Description and Operation Passenger Airbag Fig.14 Passenger Airbag Location PASSENGER AIRBAG MODULE (PAB) 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, 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. THE AIRBAG MODULE 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 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). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Airbag > Page 4918 Air Bag: Description and Operation Seat Airbag Fig.18 Seat Airbag - Typical SEAT AIRBAG MODULE 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Fig.1 Battery Negative Cable Remove/Install 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 4921 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 clockspring must also be replaced. Refer to Electrical, Restraints, Clockspring, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 4922 Air Bag: Service and Repair Passenger Airbag REMOVAL Non-Deployed Module When removing a module 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. 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. Fig.16 Airbag Connector 8. Lift the airbag up until the wire connector is visible and disconnect the 4-way wire connector from the airbag. Unlock the red locking tab and compress lock to release the connector. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 4923 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. 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 4-way wire connector from the airbag. Unlock the red locking tab and compress lock to release the connector. INSTALLATION When installing a module for any reason other than DEPLOYMENT. 1. Connect the 4-way wire connector to the airbag. Lock the red locking tab after the connector is seated. 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 module 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. 2 Nm (20 in. lbs.) torque. 4. Install the three passenger airbag cover screws attaching cover to top of instrument panel. 2 Nm (20 in. lbs.) torque. 5. Install the door onto the instrument panel and install the three screws to the glove box door. 2 Nm (20 in. lbs.) torque. 6. Install the instrument panel top cover. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 4924 Air Bag: Service and Repair Seat Airbag REMOVAL 1. Position the left front seat in the full forward position. 2. Open hood. Fig.19 Battery Negative Cable Remove/Install 3. Disconnect and isolate the battery negative cable. 4. Remove front seat from vehicle. Fig.20 Front Seat Back Panel - Typical 5. Remove plastic back panel from the seat back. 6. Disengage seat back trim cover J-strap from the upper, lower and airbag side of seat back. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 4925 Fig.21 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 4926 Fig.22 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. Install four screws in the upper mounting location of the back cover. 7. Install the front seat back in vehicle. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Airbag Control Module Air Bag Control Module: Locations Airbag Control Module The Airbag Control Module (ACM) is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Airbag Control Module > Page 4931 Air Bag Control Module: Locations Side Impact Airbag Control Module (SIACM) Fig.24 Side Impact Airbag Control Module (SIACM) Location 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 4932 Air Bag Control Module: Diagrams Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Airbag Control Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 4933 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. - THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) Air Bag Control Module: Description and Operation Airbag Control Module (ACM) Fig.3 Airbag Control Module (ACM) Location AIRBAG CONTROL MODULE The Airbag Control Module (ACM) contains the sensing element, safing sensor, and energy reserve capacitor. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. 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 warning equipment is tested for 6 - 8 seconds every time the vehicle is started and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. 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 micro- processor 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 4936 Air Bag Control Module: Description and Operation Side Impact Airbag Control Module (SIACM) Fig.24 Side Impact Airbag Control Module (SIACM) Location SIDE IMPACT AIRBAG CONTROL MODULES 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 airbag. 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 circuit 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. SEAT AIRBAG MODULES 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. THE SEAT 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). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4939 AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4940 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.19 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. 5. Remove the seat belt retractor. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4941 Fig.24 Side Impact Airbag Control Module (SIACM) Location 6. Remove the SIACM retaining nuts and ground eyelet. 7. Pull SIACM out of B-pillar. Fig.25 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4942 3. Install the seat belt retractor. 4. Install the lower B-pillar trim. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4947 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4948 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4949 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4950 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4951 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4952 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 4957 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4958 Clockspring Assembly / Spiral Cable: Locations Fig.9 Clockspring Location Clockspring The clockspring is mounted to the steering column behind the steering wheel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4959 Clockspring Assembly / Spiral Cable: Diagrams Clockspring Clockspring Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4960 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4961 Clockspring Assembly / Spiral Cable: Description and Operation Fig.9 Clockspring Location 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4962 Clockspring Assembly / Spiral Cable: Adjustments If the rotating tape within the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail during use. The following procedure MUST BE USED to center the clockspring if: - The clockspring is not known to be properly positioned. - The front wheels were moved. - The steering wheel was moved from the half turn (180 degrees) to the right (clockwise) position. 1. Remove clockspring. Refer to Electrical, Restraints, clockspring, Removal. 2. Rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of travel. Do not apply excessive torque. 3. From the end of travel, rotate the rotor 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 clockspring locking mechanism. 4. Install the clockspring. Refer to Electrical, Restraints, clockspring, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4963 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. Fig.1 Battery Negative Cable Remove/Install 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 Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 7. Disconnect the 7-way connector between the clockspring and the instrument panel wiring harness at the base of the clockspring. Fig.10 Clockspring Latch Hooks 8. Remove clockspring by lifting the top latch tab up slightly to guide it over the lock housing. The clockspring cannot be repaired, and must be replaced if faulty. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 4964 9. Rotate clockspring rotor a half turn (180 degrees) to the left (counter clockwise). 10. Lock the clockspring rotor in the center position as follows: Insert a paper clip wire through the hole in the rotor at the 10 O'clock position and bend to prevent it from falling out. INSTALLATION 1. Confirm that: - The steering wheel position is a half turn (180 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 clockspring, remove locking wire and rotate clockspring rotor one half turn (180 degrees) to the right (clockwise). Locate the clockspring on the steering shaft and push down on the rotor until the clockspring is fully seated on the steering column. - When installing a new clockspring, position the front wheels straight a head. Remove grenade pin. Rotate clockspring rotor one half turn (180 degrees) to the right (clockwise). 2. Connect the clockspring to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged and the halo lamp wire is in position. 3. Install the multi-function switch. Refer to Electrical, 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 clockspring. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Airbag Control Module Air Bag Control Module: Locations Airbag Control Module The Airbag Control Module (ACM) is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Airbag Control Module > Page 4973 Air Bag Control Module: Locations Side Impact Airbag Control Module (SIACM) Fig.24 Side Impact Airbag Control Module (SIACM) Location 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 4974 Air Bag Control Module: Diagrams Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Airbag Control Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 4975 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. - THE MODULES CANNOT BE INTERCHANGED. THEY ARE UNIQUE TO EACH SIDE. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) Air Bag Control Module: Description and Operation Airbag Control Module (ACM) Fig.3 Airbag Control Module (ACM) Location AIRBAG CONTROL MODULE The Airbag Control Module (ACM) contains the sensing element, safing sensor, and energy reserve capacitor. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. 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 warning equipment is tested for 6 - 8 seconds every time the vehicle is started and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. 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 micro- processor 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 4978 Air Bag Control Module: Description and Operation Side Impact Airbag Control Module (SIACM) Fig.24 Side Impact Airbag Control Module (SIACM) Location SIDE IMPACT AIRBAG CONTROL MODULES 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 airbag. 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 circuit 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. SEAT AIRBAG MODULES 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. THE SEAT 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). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4981 AND TESTING - AIRBAG SYSTEM FIRST. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4982 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.19 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. 5. Remove the seat belt retractor. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4983 Fig.24 Side Impact Airbag Control Module (SIACM) Location 6. Remove the SIACM retaining nuts and ground eyelet. 7. Pull SIACM out of B-pillar. Fig.25 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Airbag Control Module > Page 4984 3. Install the seat belt retractor. 4. Install the lower B-pillar trim. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 4989 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Locations Child Seat Tether Attachment: Locations Fig.6 Child Tether Anchor The Child Tether Anchor is located on the rear shelf panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Locations > Page 4994 Child Seat Tether Attachment: Description and Operation Fig.5 Child Tether Assembly Fig.6 Child Tether Anchor Fig.7 Child Tether Assembly Cap 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Locations > Page 4995 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 5000 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 5001 Seat Belt: Testing and Inspection 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 attaching seat belt buckle to seat anchor. Tighten seat belt anchor bolt to 40 Nm (30 ft. lbs.) torque. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 5007 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 40 Nm (42 ft. lbs.) torque. 2. Install rear seat cushion. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair 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. Fig.23 Front Shoulder Belt Adjuster Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 5011 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. 3. Install B-pillar trim. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation 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 always illuminate the seat belt reminder lamp for four to eight seconds when the ignition switch is turned to the ON position. The CHIME will sound during the same time interval if the driver's seat belt is not fastened. Passenger belts are not connected to the system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5023 Seat Belt Retractor: Service and Repair Rear 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.17 Rear Seat Belt And 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5029 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5030 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5031 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5032 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5033 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5034 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Antenna Mast - Installation Antenna Mast: Technical Service Bulletins Antenna Mast - Installation NUMBER: 08-21-00 GROUP: Electrical DATE: JUNE 9, 2000 SUBJECT: Antenna Mast Installation MODELS: 2000 - 2001 (PL) Neon Figure 1 DISCUSSION: The Neon antenna mast is installed at the dealership during new vehicle preparation. Recently antenna masts have been coming into the material return center with mounting surfaces stripped. The Neon antenna should be torqued to 3.2 Nm (28 In. lbs.). With the antenna mast torqued to the proper amount (3.2 Nm ( 28 in. lbs)) there will be a slight gap between the mast and the base (Figure 1). The gap is there to ensure that there is no contact between the bottom of the antenna mast and the plastic surrounding the metal insert on the base. Do not attempt to close the gap between the antenna mast and the base. POLICY: Information Only Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Page 5041 Antenna Mast: Service and Repair REMOVAL Antenna Mast Remove/Install - Typical 1. Remove antenna mast by unscrewing mast from antenna body. 2. 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 3. Unfasten push pins from the rear of the plastic inner fender shield and move shield to gain access to the base/cable assembly. 4. 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 (65 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Testing and Inspection Antenna Cable: Testing and Inspection The antenna has a short cable which connects into the instrument panel harness. The connection is made on the passenger side of the instrument panel. Antenna performance may be tested by substituting a known good antenna. It is also possible to check short or open circuits with an ohmmeter or continuity light once the antenna cable is disconnected from the radio as follows: Antenna Test Points 1. Continuity should be present between the antenna mast and radio end pin of antenna cable plug. 2. No continuity should be observed or a very high resistance of several megaohms between the ground shell of the connector and radio end pin. 3. Continuity should be observed between the ground shell of the connector and the mounting hardware on the vehicle antenna. The wheel well splash shield must be removed for access to the antenna that is mounted on the load beam. It is also possible to check short or open circuits with an ohmmeter or continuity light once the antenna has been removed from the vehicle. Fig.7 Antenna Bench Test Points 4. Continuity should be present between the tip of the mast and radio lead in. 5. No continuity should be observed or a very high resistance of several megaohms between the ground shell of the connector and radio end pin. 6. Continuity should be observed between the ground shell of the connector and the mounting bracket. Wiggle cable over its entire length to reveal intermittent short or open circuits during step 1, 2 and 3. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Testing and Inspection > Page 5046 Antenna Cable: Service and Repair REMOVAL Antenna Mast Remove/Install - Typical 1. Remove antenna mast by unscrewing mast from antenna body. 2. 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 3. Unfasten push pins from the rear of the plastic inner fender shield and move shield to gain access to the base/cable assembly. 4. 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 (65 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5056 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5062 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5063 Alarm Module: Locations Sentry Key Immobilizer (SKIM) Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5064 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5065 Alarm Module: Description and Operation Sentry Key Immobilizer (SKIM) Location SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) (Fig.9) 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 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. Refer to Electrical, Vehicle Theft Security Transponder Key, Standard Procedure - Sentry Key Immobilizer System Transponder programming. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5066 Alarm Module: Testing and Inspection To Switch Operating Modes or to Configure A New Module, a DRBIII(R) scan tool must be used. Fig.10 Data Link Connector (DLC) Location 1. Hook up the DRBIII(R) scan tool to the Data Link Connector (DLC). 2. With the key in the ignition, turn the key to the RUN position. 3. After the DRBIII(R) scan tool initialization, perform the following: a. Select "Theft Alarm." b. Select "VTSS." c. Select "Miscellaneous," 4. Once in the "Miscellaneous" screen: a. If you wish to configure a new module, select "Configure Module." b. If you wish to put the module into customer usage mode, select "Enable VTSS." c. If you wish to put the module into dealer lot mode, select "Dealer Lot." Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 5070 Alarm System Transponder: Service and Repair 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(R) scan tool: 1. Insert the blank key into the ignition and turn it to the RUN position. 2. Using a DRB III(R) scan tool, select "Theft Alarm," "SKIM," "Miscellaneous," and then "Program New 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(R) 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(R) 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 within 15 seconds of removing the first valid Sentry key. 4. About ten 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 sixty 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 ten 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 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 fifty (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. - Once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative remote cable. 3. Using a trim stick (special tool #C-4755) or equivalent, gently pry switch up and out of mounting bracket. 4. Disconnect wire harness connector from hood ajar switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch in vehicle. 2. Connect wire harness connector to hood ajar switch. 3. Firmly snap hood ajar switch into mounting bracket. 4. Connect the battery negative remote cable. 5. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Diagrams RKE Antenna (Japan) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5086 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5092 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5093 Keyless Entry Module: Locations Fig.3 RKE Module Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5094 Remote Keyless Entry Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5095 Keyless Entry Module: Description and Operation 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5096 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5097 Keyless Entry Module: Service and Repair REMOVAL Fig.1 Battery Negative Cable Remove/Install 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. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5098 NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.2 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 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 (one or two times depending on customer preference) within a two 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 5102 Fig.2 Remote Keyless Entry Transmitter 1. With the ignition switch in RUN position, press and hold the transmitter Unlock button for a minimum of 4 seconds to a maximum of 10 seconds. 2. Within the 4-10 second range, depress the transmitter Lock button. A chime will be heard to indicate successfull toggle, at which time the buttons may be released. 3. Turn the ignition switch OFF to exist transmitter programming mode. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5106 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch Passenger Cylinder Lock Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5107 Lock Cylinder Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Application and ID > Page 5111 Security Lamp/Indicator: Description and Operation The Sentry Key Immobilizer System (SKIS) uses an indicator light to convey information on the status of the system to the customer. This light is shared with the Vehicle Theft Security System (VTSS). The light is located in the instrument cluster and is shared with the Vehicle Theft Security System. The indicator light is controlled by the instrument cluster based upon messages it receives from the Sentry Key Immobilizer Module (SKIM) on the PCI bus. The SKIM sends messages to the instrument cluster to turn the light ON for three (3) seconds when the ignition switch is turned to the ON position as a power-up test. After completion of the power-up test, the SKIM sends a message on the PCI bus to keep the light OFF for a duration of one second. Then, the SKIM sends messages to the instrument cluster to operate the light based upon the results of the SKIS self tests. The light may be actuated in two possible ways, flashing or ON solid. If the light comes ON and stays ON solid after a power-up test, this indicates that the SKIM has detected a system malfunction. If the SKIM detects an invalid key when the ignition switch is moved to the ON position, it sends a message on the PCI bus to flash the light. The SKIM can also send a message to flash the light and generate a single audible chime at the same time. These two events occurring simultaneously indicate that the SKIS has been placed into the "Customer Learn" mode. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Sentry Key Immobilizer System Transponder programming for more information on the "Customer Learn" mode. If the light comes ON and stays ON after the power-up test, diagnosis of the SKIS should be performed using a DRB III scan tool and the appropriate Body Diagnostic Procedures. The light is not a serviceable component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions CD Changer: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 CD Changer: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 CD Changer Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 5137 CD Changer: Service and Repair REMOVAL Fig.10 Battery Negative Cable Remove/Install 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.11 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. Install CD changer to vehicle. 2. Connect harness connector to CD changer. 3. Install retaining screws. 4. Install CD changer bezel. 5. Connect battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Radio/Stereo: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Radio/Stereo: Connector Views Radio C1 Radio C2 Radio C3 Radio C4 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Radio/Stereo: Electrical Diagrams Audio System Wiring Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 8w-47-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 8w-47-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 8w-47-4 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 8w-47-5 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5166 Radio/Stereo: Description and Operation AUDIO The audio system on the 2001 PL consists of a radio that communicates over the PCI bus. There are two different system combinations available on the PL models. The available radio options are: AM/FM Cassette with CD Changer Controls and Display - CD/4 Disc Changer In-Dash (used with Radio CD Changer Controls Each radio system comes equipped with a standard premium 6 speaker system. 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. Depending on the manufacture, some systems will have Front/Rear output system and others will have a Left/Right output system. 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 can display, indicating which output is effected. Operating instructions for the factory installed audio systems can be found in the Owner's Manual provided with the vehicle. The vehicles are equipped with an Interior Ignition Off Draw (IOD) fuse in the Power Distribution Center located in the engine compartment. After the Interior (IOD) fuse or battery has been disconnected, the clock will require resetting. The radio station presets have a nonvolatile memory and will retain the preset stations after a battery disconnect. RADIO NOISE SUPPRESSION COMPONENTS The radio utilizes a ground wire plugged on to a blade terminal and is bolted to the radio chassis. Both connector and terminal should be securely attached. The vehicle has the following noise suppression components which, if disconnected, may interfere with radio reception: Cylinder head to dragon's 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). - Exhaust to body ground strap. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5167 Radio/Stereo: Testing and Inspection CAUTION: The CD player will only operate between approximate temperatures of -23 °C and +65 °C (-10 °F and +145 °F). Whenever a radio malfunction occurs, first check the Power Distribution Center (PDC), Interior lamp fuse, M1 - Radio Memory Feed. Also, check Fuse 2 in the fuse block. NOTE: The vehicles are shipped with the INTERIOR LAMP fuse disconnected. AM/FM Stereo (Part 1 Of 5) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5168 AM/FM Stereo (Part 2 Of 5) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5169 AM/FM Stereo (Part 3 Of 5) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5170 AM/FM Stereo (Part 4 Of 5) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5171 AM/FM Stereo (Part 5 Of 5) Verify, the radio wire harness are properly connected before starting normal diagnosis and repair procedures. Refer to,,,,. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5172 Radio/Stereo: Service and Repair REMOVAL Fig.10 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel center bezel. Fig.12 Radio Remove/Install 3. Remove four mounting screws on the radio and pull out of instrument panel. 4. Disconnect wiring and antenna cable and remove ground wire from radio. 5. Remove radio from vehicle. INSTALLATION 1. Install radio to vehicle. 2. Connect wiring, antenna cable and ground strap to radio. 3. Install mounting screws. 4. Install instrument panel center bezel. 5. Connect battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Right Rear Speaker Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speaker Replacement Speaker: Service and Repair Door Mounted Speaker Replacement REMOVAL Fig.10 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. Fig.13 Front Door Speaker Remove/Install 3. Remove speaker retaining screws. 4. Remove speaker assembly and disconnect wire connector from rear of speaker. INSTALLATION 1. Reconnect 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speaker Replacement > Page 5178 Speaker: Service and Repair Instrument Panel Speaker Replacement REMOVAL Fig.10 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Fig.14 Instrument Panel Speaker 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speaker Replacement > Page 5179 Speaker: Service and Repair Rear Shelf Speaker Replacement REMOVAL Fig.10 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable. 2. Remove Rear Seat Cushion. 3. Remove rear seat back. 4. Remove rear shelf panel. Fig.15 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. Reconnect wire connector to the speaker. 2. Install speaker to the vehicle. 3. Install speaker retaining screws. 4. Install rear shelf panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speaker Replacement > Page 5180 5. Install seat back. 6. Install rear seat cushion. 7. Reconnect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5190 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5196 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5197 Alarm Module: Locations Sentry Key Immobilizer (SKIM) Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5198 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5199 Alarm Module: Description and Operation Sentry Key Immobilizer (SKIM) Location SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) (Fig.9) 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 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. Refer to Electrical, Vehicle Theft Security Transponder Key, Standard Procedure - Sentry Key Immobilizer System Transponder programming. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 5200 Alarm Module: Testing and Inspection To Switch Operating Modes or to Configure A New Module, a DRBIII(R) scan tool must be used. Fig.10 Data Link Connector (DLC) Location 1. Hook up the DRBIII(R) scan tool to the Data Link Connector (DLC). 2. With the key in the ignition, turn the key to the RUN position. 3. After the DRBIII(R) scan tool initialization, perform the following: a. Select "Theft Alarm." b. Select "VTSS." c. Select "Miscellaneous," 4. Once in the "Miscellaneous" screen: a. If you wish to configure a new module, select "Configure Module." b. If you wish to put the module into customer usage mode, select "Enable VTSS." c. If you wish to put the module into dealer lot mode, select "Dealer Lot." Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5209 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5215 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5216 Keyless Entry Module: Locations Fig.3 RKE Module Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5217 Remote Keyless Entry Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5218 Keyless Entry Module: Description and Operation 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5219 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5220 Keyless Entry Module: Service and Repair REMOVAL Fig.1 Battery Negative Cable Remove/Install 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. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5221 NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative remote cable. 3. Using a trim stick (special tool #C-4755) or equivalent, gently pry switch up and out of mounting bracket. 4. Disconnect wire harness connector from hood ajar switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch in vehicle. 2. Connect wire harness connector to hood ajar switch. 3. Firmly snap hood ajar switch into mounting bracket. 4. Connect the battery negative remote cable. 5. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 5229 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch Passenger Cylinder Lock Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 5230 Lock Cylinder Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation, this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set making diagnosis of the original problem more difficult. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation Body Control Module: Description and Operation System Description and Functional Operation SYSTEM DESCRIPTION The body system on the 2001 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 of this general information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5238 Body Control Module: Description and Operation Functional Operation Part 1 of 2 FUNCTIONAL OPERATION 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 micro-processor 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. Driver Airbag Module (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. THE AIRBAG MODULE 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5239 Passenger Airbag Module (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. THE AIRBAG MODULE 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 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). 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 Airbag Modules 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. THE SEAT 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). 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. ACM/SIACM 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5240 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 minmum 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. AUDIO SYSTEM The audio system on the 2001 PL consists of a radio that communicates over the PCI bus. Each radio system comes equipped with a standard premium 6 speaker system. 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. Depending on the manufacture, some systems will have Front/Rear output system and others will have a Left/Right output system. 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 can display, indicating which output is effected. 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. Part 2 of 2 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) For the domestic market there are 2 (two) Instrument Cluster types, Base and Premium. The Premium Instrument Cluster is equipped with a Tachometer and a Low Fuel indicator. 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 to display PCI Engine Info, PCI Bus info, and certain inputs/outputs. The Cluster is also capable Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5241 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. INTERIOR LIGHTING The Courtesy Lamps are controlled by the instrument cluster. The instrument cluster is sometimes referred to as a "Smart Cluster Control Module". 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. 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Vehicle Theft Security System The VTSS monitors the vehicle doors, decklid, hood and the ignition for unauthorized operation. Additionally, the decklid key cylinder is monitored for tampering, such as attempts to punch out the key cylinder. The alarm activates by sounding the horn, flashing the headlamps, park lamps and the VTSS indicator in the instrument cluster. Locking the doors with the door lock switch (through following a normal exit sequence of opening the door, pressing the lock button, and closing the door), the door cylinder lock switches or the RKE transmitter arms the system. During the 16 second arming process the VTSS indicator will flash quickly and when the system is armed will slow down. THE SYSTEM WILL NOT ARM IF THE HOOD IS OPEN (switch is grounded), or the decklid security switch (knockout) is not grounded, the LED will stay ON steady during arming. The engine kill feature on domestic vehicles is accomplished via the Sentry Key Immobilizer Module (SKIM). All of the sensors for the VTS 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. Power Door Locks Central Locking This feature allows the customer to lock/unlock all vehicle doors with the key from either front door cylinder lock switch. The customer can choose to program this feature to unlock all doors with one turn of the key or open the driver door only with the first turn of the key and open the other doors with the second turn. Altering the operation of the unlock function via the key cylinder switch from one turn to two turns will also alter the operation of the RKE transmitter from one press to two presses. Rolling (Automatic) Door Locks All vehicle doors are locked automatically once the vehicle reaches a speed of 15 mph and all doors are closed. This feature can be also be enabled! disabled by the customer. Door Lock Inhibit This feature disables the door lock command from the interior door lock switch whenever the driver door is open and the key is in the ignition. This prevents the driver from locking the keys in the ignition when using the power door locks. This feature is inoperable if the IOD fuse is not installed. Power Decklid Release Electrically releases the decklid upon two presses of the RKE transmitter decklid release button. This feature is disabled once the speed of the vehicle is greater than 5 mph. This feature may be altered with the DRB III to allow the decklid to be released with one press of the RKE transmitter decklid release button. The decklid can also be released from the switch in the glove box. Panic Mode Upon activation of the panic function, the headlamps and park lamps flash in an alternating manner, the horn pulses every second and the courtesy lamps are turned ON. The panic mode allow normal nighttime driving by allowing the headlamps and park lamps to be on steady when the headlamp switch is in the ON position. Panic mode is activated immediately by pressing the panic button once. It does not disarm the VTSS or unlock the doors. It is canceled by pressing the button a second time, reaching a vehicle speed greater than 15 mph or after 3 minutes has elapsed in panic mode. Once panic mode has been activated there is a 2-second delay before it will turn OFF. Once it is cancelled there is a 2-second delay before it can be reactivated. This is to avoid the problem of deactivating and immediate reactivating due to multiple Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5242 button presses. 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 and is violet with a yellow tracer. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on 2001 PL: Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - Powertrain Control Module - Radio - CD Changer - Remote Keyless Entry Module - Sentry Key Immobilizer Module - Transmission Control 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5243 are transmitting and is pulled up to about seven and a half volts when modules are transmitting. 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 12V 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 figure 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 module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description and Functional Operation > Page 5244 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 +/- 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle 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. 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5247 Body Control Module: Scan Tool Testing and Procedures 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5248 Down or Page Up function to display the information. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 5249 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Test Light Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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). 3. Disconnect fog lamp wiring harness, if equipped. Fig. 2 4. Remove nuts attaching front bumper fascia to bottom of fender flange (Fig. 2). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 5255 5. Remove fascia from vehicle. INSTALLATION 1. Position fascia on vehicle (Fig. 2). 2. Install nuts attaching front bumper fascia to bottom of fender flange. 3. Attach fascia horns to radiator crossmember. 4. Install air dam to crossmember fasteners (Fig.1). 5. Install splash shield attaching screws. 6. Connect fog lamp wiring harness. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 3 3. Remove nuts attaching reinforcement to the rail assembly (Fig. 3). 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. 3). 3. Support bumper reinforcement on a suitable lifting device. 4. Install nuts attaching reinforcement to rail assembly. 5. Install front fascia. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 4 2. Remove nuts attaching fascia in the trunk (Fig. 4). 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. 4). 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 nuts attaching fascia in the trunk. 8. Close decklid. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 5 1. Remove rear fascia (Fig. 5). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair 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. 7 3. Remove body vent from vehicle (Fig. 7). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 holding cowl cover to cowl at base of windshield opening (Fig. 1). 4. Remove hood to cowl seal, at the leading edge of cowl cover. Pull the seal towards the front of the vehicle. 5. Separate the cowl cover from the vehicle. INSTALLATION 1. Place cowl panel in place on vehicle. 2. Install the five screws holding cowl panel to cowl at base of windshield opening. 3. Push the hood to cowl seal over the forward flange of the cowl cover and cowl plenum. 4. Install windshield wiper arms. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove door trim panel and water dam. 2. Close door glass. 3. Disconnect lock and latch rods from door latch. Fig. 6 4. Remove nut attaching door handle retainer to outer door panel (Fig. 6). 5. Remove retainer from back of door handle. 6. Remove door handle from vehicle. INSTALLATION 1. Position door handle into door and install retainer at back of handle. 2. Install nut attaching door handle retainer to outer door panel. 3. Connect lock and latch rods to door latch. 4. Install door trim panel and water dam. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 3 4. Remove bolts attaching hinge to door end frame (Fig. 3). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 5286 Front Door Latch: Service and Repair LATCH REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. Fig. 7 3. Disconnect lock and latch rods from door latch (Fig. 7). 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 in this section. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 2 5. Remove bolts attaching check strap to door end frame (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 12 3. Remove window regulator crank, if so equipped (Fig. 12). Fig. 10 4. Remove screw from inside arm rest pull cup (Fig. 10). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Trim Panel > Page 5294 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Trim Panel > Page 5295 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. 11 5. Peel water dam away from adhesive around perimeter of inner door panel (Fig. 11). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 8 2. Remove screws attaching door latch striker to B-pillar (Fig. 8). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair B-PILLAR WEATHERSTRIP CHANNEL REMOVAL Fig. 1 1. Remove B-pillar applique (Fig. 1). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door Front Door Window Glass Weatherstrip: Service and Repair Front Door 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-one 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5307 Front Door Window Glass Weatherstrip: Service and Repair FDR Glass Run Weatherstrip FOR 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. 2 6. Pull run weatherstrip from window frame channel (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5308 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. 3 3. Remove outer belt weatherstrip from vehicle (Fig. 3). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5309 Front Door Window Glass Weatherstrip: Service and Repair 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5310 Front Door Window Glass Weatherstrip: Service and Repair Front Door 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-one 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. FDR Glass Run Weatherstrip FOR 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. 2 6. Pull run weatherstrip from window frame channel (Fig. 2). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5311 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. Fig. 3 3. Remove outer belt weatherstrip from vehicle (Fig. 3). 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5312 FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 4 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. 4). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5313 Fig. 8 1. Using a fork-type prying tool, disengage push in fasteners attaching sill secondary weatherstrip to door (Fig. 8). 2. Remove weatherstrip from door. 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. 9 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Door > Page 5314 2. Pull decklid weatherstrip form decklid opening fence (Fig. 9). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Battery Negative Cable Remove/Install 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 4 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. 4). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5324 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. 5 5. Pull run weatherstrip from window frame channel (Fig. 5). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5325 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REMOVAL 1. Remove door trim panel. 2. Remove door glass from regulator channel. Rear Door Glass 3. Loosen screws attaching window regulator channel and crank housing to door panel. 4. Disengage screw and bolt heads from keyhole slots in door panel. 5. Loosen bolts attaching window regulator to door panel. 6. Disengage regulator from door panel, and crank housing. 7. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel, 8. 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. Position glass to regulator roller channel. 6. Tighten fasteners attaching door glass to roller channel. 7. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 5330 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Remove door glass from regulator channel. Fig. 3 3. Loosen screws attaching window regulator channel and crank housing to door panel (Fig. 3). 4. Disengage screw and bolt heads from keyhole slots in door panel. 5. Loosen bolts attaching window regulator to door panel. 6. Disengage regulator from door panel, and crank housing. 7. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. 8. 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. Position glass to regulator roller channel. 6. Tighten fasteners attaching door glass to roller channel. 7. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open the fuel filler door. Fig. 4 2. Remove the screws attaching the door to the quarter panel (Fig. 4). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 6 2. Disconnect hood lamp wire connector and remove hood lamp (Fig. 6). 3. Remove fasteners attaching hood silencer to hood. 4. Remove hood silencer from vehicle. INSTALLATION 1. Place hood silencer in position on vehicle. 2. Install fastener attaching hood silencer to hood. 3. Install hood lamp and connect wire connector. 4. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1. Release hood latch and open hood. 2. Support hood on prop rod. 3. Remove grille. Fig. 4 4. Remove screws attaching hood latch to radiator closure panel (Fig. 4). 5. Remove hood latch from closure panel. 6. Disengage remote release cable from latch. INSTALLATION 1. Engage remote release cable into latch. 2. Place hood latch onto radiator closure panel. 3. Install bolts attaching latch to closure panel. 4. Install grille. 5. Close hood and verify alignment of hood and that latch is securely engaged. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Disconnect remote hood release cable from hood latch. 2. Remove left front cowl trim panel. Fig. 5 3. Remove screws attaching hood release handle to cowl panel (Fig. 5). 4. Disconnect rubber grommet from dash panel behind instrument panel. 5. Pull release cable through hole in dash panel. 6. Remove cable and handle from vehicle. INSTALLATION 1. Assemble cable and handle onto vehicle. 2. Push release cable through hole in dash panel. 3. Connect rubber grommet into dash panel. 4. Install screws attaching hood release handle to cowl panel. 5. Install left front cowl trim panel. 6. Connect remote hood release cable to hood latch. 7. Close hood and verify operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative remote cable. 3. Using a trim stick (special tool #C-4755) or equivalent, gently pry switch up and out of mounting bracket. 4. Disconnect wire harness connector from hood ajar switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch in vehicle. 2. Connect wire harness connector to hood ajar switch. 3. Firmly snap hood ajar switch into mounting bracket. 4. Connect the battery negative remote cable. 5. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Position latch in vehicle and engage decklid ajar switch connector to latch. 2. Connect remote decklid latch release cable to decklid latch. 3. Install bolts attaching decklid latch to decklid lid. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 5 2. Unclip cable and handle assembly (Fig. 5). INSTALLATION 1. Attach emergency release cable clip to the latch stud. 2. Install the decklid cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1. Remove decklid latch. 2. Remove clip attaching decklid lock cylinder to decklid. Fig. 2 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 5370 Decklid Solenoid Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 5371 Trunk / Liftgate Solenoid: Testing and Inspection 1. Confirm operation of RKE transmitters. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 5372 Trunk / Liftgate Solenoid: Service and Repair Fig.1 Battery Negative Cable Remove/Install 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 CAN RESULT. 1. Release and open decklid. 2. Support decklid on a suitable prop device. Fig. 2 3. Pull split cover from lift spring (Fig. 2). 4. Using a common pliers, disengage spring from adjustment slot under decklid opening side trough. 5. Disengage spring from decklid hinge. INSTALLATION 1. Engage spring to decklid hinge. 2. Engage spring to the adjustment slot under decklid opening side trough. 3. Remove decklid support device. 4. Close decklid. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations The Vehicle Theft Security System (VTSS) Deck Lid Security Switch is mounted to the back of the deck lid lock cylinder. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 5382 Trunk / Liftgate Switch: Diagrams Decklid Release Switch (Power Release) Decklid Security Switch (Knock Out) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Decklid Release Switch Replacement Trunk / Liftgate Switch: Service and Repair Decklid Release Switch Replacement 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Decklid Release Switch Replacement > Page 5385 Trunk / Liftgate Switch: Service and Repair Decklid Security Switch Replacement 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 holding cowl cover to cowl at base of windshield opening (Fig. 1). 4. Remove hood to cowl seal, at the leading edge of cowl cover. Pull the seal towards the front of the vehicle. 5. Separate the cowl cover from the vehicle. INSTALLATION 1. Place cowl panel in place on vehicle. 2. Install the five screws holding cowl panel to cowl at base of windshield opening. 3. Push the hood to cowl seal over the forward flange of the cowl cover and cowl plenum. 4. Install windshield wiper arms. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Refer to Vehicle Lifting. 2. Remove front wheel. Fig. 2 3. Remove push-in fasteners attaching splash shield to frame rail forward of suspension (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 8 2. Remove the two screws and the three push-pin fasteners (Fig. 8). INSTALLATION 1. Install the shield. 2. Install the three push-pin fasteners and two screws. 3. Install the wheel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5407 Front Cross-Member: Service and Repair REMOVAL 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. Refer to Vehicle Lifting. 2. Remove both front tire and wheel assemblies from the vehicle. Fig. 10 3. Remove both stabilizer bar links from the vehicle (Fig. 10). 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. 10), and remove the stabilizer bar with cushions attached from the vehicle. Fig. 11 5. Remove the nut and pinch bolt clamping each ball joint stud to the steering knuckle (Fig. 11). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5408 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 CN joint on the driveshaft. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut. Fig. 12 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. 12). 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. 13 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5409 9. Loosen and remove the four bolts attaching the power steering gear to the front suspension crossmember (Fig. 13). Remove the power steering gear from the front suspension crossmember. 10. Remove the drive-belt splash shield fasteners. Remove the shield. Fig. 14 11. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle (Fig. 14). Remove the washer behind the strut from the torque strut bolt. 12. Remove the bolts mounting the engine torque strut in place (Fig. 14), then remove the engine torque strut from the vehicle. NOTE: Before removing the front suspension cross-member from the vehicle, the location of the crossmember 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. 15 13. Using an awl, scribe a line (Fig. 15) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5410 Fig. 16 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. 16). 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. 16). 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 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. 16). 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. 15). 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. 13). 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. 11). Tighten the nut to a torque of 95 N.m (70 ft.lbs.). 11. Install the engine torque strut and mounting bolts (Fig. 14). 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. 14). 13. Install the pencil strut to the right front corner of the crossmember and body of the vehicle (Fig. 14). Tighten the pencil strut nuts to a torque of 58 N.m (43 ft.lbs.). 14. Install the drive-belt splash shield and fasteners. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Description and Operation > Page 5411 Fig. 17 NOTE: Before installing the stabilizer bar, make sure the bar is not upsidedown. 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. 17). 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. 10). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Fig. 5 2. Remove screws attaching grille to fascia (Fig. 5). 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. Align lower grille clips and center grille tab into fascia slots. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 5420 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Application and ID Console: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures Console: Procedures FLOOR CONSOLE 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. 3. Install shift lever knob, if vehicle is equipped with a manual transmission. 4. Release parking brake. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 5426 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5431 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small screwdriver into notch by lens arid gently pry out unit. 3. Slide back rear cover to expose bulb. 4. Remove bulb. INSTALLATION 1. Install bulb. 2. Insert bulb into cover. 3. Align bulb holder with slots on instrument panel and firmly snap into place. 4. Connect battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 5440 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair SUN VISOR REMOVAL 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. 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 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures STANDARD PROCEDURE 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5454 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5455 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5456 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5457 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5458 Fig. 3 5. Remove bolt attaching turning loop to belt adjuster (Fig. 3). 6. Remove access cover from B-pillar trim. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5459 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5460 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5461 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair Utility Storage Compartment: Service and Repair STORAGE BIN REMOVAL 1. Using a trim stick (special tool #C-4755) or equivalent, gently pry out on the side of the lower storage bin. 2. Disconnect the center console flood lamp. 3. Transfer the center console flood lamp housing to new bin (if replacing). INSTALLATION 1. Transfer the center console flood lamp housing to new bin (if replacing). 2. Connect the center console flood lamp. 3. Position the storage bin over mounting slots and firmly snap into place. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 9 5. Pull lock cylinder from door handle (Fig. 9). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Diagrams RKE Antenna (Japan) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5482 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5488 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5489 Keyless Entry Module: Locations Fig.3 RKE Module Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5490 Remote Keyless Entry Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5491 Keyless Entry Module: Description and Operation 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5492 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5493 Keyless Entry Module: Service and Repair REMOVAL Fig.1 Battery Negative Cable Remove/Install 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. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5494 NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation Fig.2 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 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 (one or two times depending on customer preference) within a two 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 5498 Fig.2 Remote Keyless Entry Transmitter 1. With the ignition switch in RUN position, press and hold the transmitter Unlock button for a minimum of 4 seconds to a maximum of 10 seconds. 2. Within the 4-10 second range, depress the transmitter Lock button. A chime will be heard to indicate successfull toggle, at which time the buttons may be released. 3. Turn the ignition switch OFF to exist transmitter programming mode. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 5503 Power Door Lock Actuator: Diagrams Driver Door Lock Motor/Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 5504 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 maybe 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 5508 Power Door Lock Switch: Testing and Inspection 1. Remove the switch from its mounting location, and disconnect from vehicle wiring harness. Door Lock Switch Resistance 2. Using an ohmmeter, refer to the table to determine if switch resistance is correct in the Lock and Unlock switch positions. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 5509 Power Door Lock Switch: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 1. Remove decklid latch. 2. Remove clip attaching decklid lock cylinder to decklid. Fig. 2 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Power Mirror Switch (LHD) Power Mirror Switch (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 5517 Power Mirror Switch: Testing and Inspection 1. Remove power mirror switch. Mirror Switch Continuity (Part 1 Of 2) Mirror Switch Continuity (Part 2 Of 2) 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Continuity table 3. If test results are not obtained as shown in the Mirror Switch Continuity table, replace the switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 5518 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID PAINT CODE Exterior vehicle body colors are identified on the Body Code plate. The plate is located on the floor pan under the passenger seat or attached to the front face of the radiator closure panel. The paint code is also identified on the Vehicle Safety Certification Label which is located on the drivers door shut face. The color names provided in the Paint and Trim Code Description chart are the color names used on most repair product containers. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 5523 Paint: Description and Operation BASE COAT/CLEAR COAT FINISH DESCRIPTION On most vehicles a two-part paint application (base coat/clear coat) is used. Color paint that is applied to primer is called base coat. The clear coat protects the base coat 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 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. WARNING: USE A OSHA APPROVED BREATHING MASK 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 defect 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 clear coat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clear coat, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 5526 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING / BUFFING & POLISHING DESCRIPTION Minor acid etching, orange peel, or smudging in clear coat 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 clear coat finish, if equipped. Base coat paint must retain clear coat for durability. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5536 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 5542 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5543 Keyless Entry Module: Locations Fig.3 RKE Module Location Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5544 Remote Keyless Entry Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5545 Keyless Entry Module: Description and Operation 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 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 and the vehicle speed is zero, 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, to receive the vehicle information number 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5546 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5547 Keyless Entry Module: Service and Repair REMOVAL Fig.1 Battery Negative Cable Remove/Install 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. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. Additionally, all transmitters must be reprogrammed to the new RKE module. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 5548 NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB III scan tool for proper operation. Refer to Electrical, Vehicle Theft/Security, Standard Procedure - Switching Operating Modes/Configuring a New Module. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Control Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 5554 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 5555 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Sunroof Motor Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 5567 Sunroof / Moonroof Motor: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 5568 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 5569 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 5573 Sunroof / Moonroof Switch: Service and Repair CONTROL UNIT REMOVAL Fig. 1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 5574 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 5575 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 (Fig. 1). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures > Page 5580 Sunroof / Moonroof Windguard: Removal and Replacement WIND DEFLECTOR REMOVAL 1. Open sunroof to full open position. Fig. 1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures > Page 5581 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures > Page 5582 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Page 5586 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Page 5587 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Control Module Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 5593 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Sunroof Module > Page 5594 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 5598 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 ± 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 5599 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures > Page 5602 Sunroof / Moonroof Panel: Removal and Replacement GLASS PANEL REMOVAL Fig. 1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures > Page 5603 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures > Page 5604 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat Seats: Service and Repair Front Seat Front Seat FRONT SEAT REMOVAL 1. Move seat to forward position. 2. Remove bolts attaching rear of seat track to floor. 3. Move seat to rearward position. Fig. 1 4. Remove bolts attaching front of seat track to floor crossmember (Fig. 1). 5. Remove seat from vehicle. INSTALLATION 1. Move seat to mid-position and verify that both seat tracks are locked into same position with eight teeth behind the latch mechanism. 2. Move seat into position in vehicle. Do not use the head restraint, side shield, recliner handle, or the adjuster lift bar to move the seat. 3. Ensure that the locating tabs on the front mounting feet are installed through the slits in the carpet and into the openings in the floor pan crossmember. 4. Install and tighten front inboard bolt attaching seat track to floor crossmember. 5. Install front outboard bolt attaching seat track to floor crossmember. Tighten front seat bolt to 55 N.m (40 ft.lbs.) torque. 6. Install rear seat track attaching bolts to floor. Tighten rear seat bolts outboard first then inboard to 55 N.m (40 ft.lbs.) torque. Front Seat Back FRONT SEAT BACK REMOVAL 1. Remove seat from vehicle. 2. Remove seat cushion side shields. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat > Page 5609 Fig. 2 3. Remove bolts attaching recliner to seat back cushion frame (Fig. 2). Fig. 3 4. Remove inboard pivot bolt (Fig. 3). 5. Disconnect any electrical connectors to the seat back, if equipped. 6. Remove seat back from seat cushion. INSTALLATION 1. Position seat back on cushion. 2. Connect electrical connectors to the seat back, if equipped. 3. Install inboard pivot bolt. Tighten bolt to 40 N.m (30 ft.lbs.) torque. 4. Install bolts attaching recliner to seat cushion frame. Tighten bolts to 12 N.m (9 ft.lbs.) torque. 5. Install seat cushion side shields. 6. Install seat in vehicle. Front Seat Back Cover FRONT SEAT BACK COVER REMOVAL 1. Remove seat from vehicle. 2. Remove head restraint. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat > Page 5610 3. Remove front seat back. 4. Disengage the J-strap retainer. Fig. 4 5. Roll cover upward to hog rings. Cut hog rings to free cover (Fig. 4). 6. Roll cover to top of seat back and remove head restraint sleeve guides. 7. Remove cover from seat back. INSTALLATION NOTE: Do not reuse the recliner assembly attaching bolts. 1. Position cover at the top of seat back. 2. Carefully roll cover down to the area that hog rings are to be installed. 3. Install hog rings. 4. Roll cover downward. 5. Engage the J-strap retainer 6. Install new head restraint sleeve guides. 7. Install seat back to seat cushion. Tighten bolts to 40 N.m (30 ft.lbs.) torque. 8. Install seat in vehicle. 9. Install head restraint. 10. Check seat back and headrest operation. Front Seat Cushion FRONT SEAT CUSHION REMOVAL 1. Remove seat from vehicle. 2. Remove front seat cushion side shield. 3. Remove seat back. 4. Remove track and recliner assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat > Page 5611 Fig. 5 5. Remove seat cushion (Fig. 5). INSTALLATION - FRONT SEAT CUSHION 1. Connect seat cushion heater element connector, if equipped. 2. Install track and recliner assembly. Tighten bolts to 12 N.m (9 ft.lbs.) torque. 3. Install seat back. Tighten bolts to 40 N.m (30 ft.lbs.) torque. (Fig. 5) 4. Install cushion side shields. 5. Install seat in vehicle. Front Seat Cushion Cover FRONT SEAT CUSHION COVER REMOVAL 1. Remove seat from vehicle. 2. Remove front seat cushion side shields. 3. Remove seat back. 4. Remove track and recliner assembly. 5. Disengage J-strap attaching seat cover from the seat cushion frame. 6. Pull cover off to the hog rings. 7. Cut hog rings attaching seat cover to seat cushion pad. 8. Remove seat cushion cover from seat cushion. INSTALLATION 1. Position seat cover on cushion. 2. Align seat cover with cushion alignment indentations. 3. Install hog rings. 4. Engage J-strap attaching seat cover to front of seat cushion frame. 5. Install track and recliner assembly. Tighten front track to pan bolts to 12 N.m (9 ft.lbs.) torque. 6. Install seat back. 7. Install front seat cushion side shields. 8. Install seat in vehicle. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat > Page 5612 Seats: Service and Repair Rear Seat Rear Seat Back REAR SEAT BACK REMOVAL 1. Remove rear seat cushion. Fig. 7 2. Remove bolts attaching rear seat back and seat belts to floor (Fig. 7). Fig. 8 3. Push rear seat back upward to disengage hooks at top of seat back (Fig. 8). 4. Remove rear seat from vehicle. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat > Page 5613 1. Move rear seat back into position in vehicle. 2. Push seat back downward to engage hooks at top of seat back. 3. Install bolts attaching rear seat back and seat belts to floor. NOTE: The torque specification for the inner seat belt/rear seat back retaining bolts is 57 N.m (42 ft.lbs.). 4. Install rear seat cushion. Rear Seat Cushion REAR SEAT CUSHION REMOVAL 1. Pull upward at each end of the rear seat cushion to disengage retainer loops from cups in floor. Fig. 6 2. Remove rear seat cushion from vehicle (Fig. 6). INSTALLATION 1. Place rear seat cushion in position under bottom of seat back. 2. Position inboard seat belts on top of seat cushion. 3. Guide seat cushion loops into retainer cups in floor pan. 4. Push downward on the front corners of the seat cushion to engage retainers. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Component Information > Service and Repair > Front Seat > Page 5614 Seats: Service and Repair Seat Back Plastic Panel SEAT BACK PLASTIC PANEL REMOVAL 1. Grasp seat back panel at upper corners. 2. Pull rearward on panel until both upper corner attaching clips disengage. 3. Remove the two lower attaching screws. 4. Remove plastic panel from seat back. INSTALLATION 1. Inspect seat back where attaching clips and screws engage into seat frame for damage or distortion. 2. If seat frame is damage or distorted repair to original flat surface. If damage or distortion beyond repair replace seat frame. 3. Inspect attaching clips for damage or deformation and replace as necessary. 4. Secure upper attachment clips to seat back plastic panel. 5. Place panel into position on seat back and press on panel until clips lock into position. 6. Install lower two screws into panel. Tighten screws to 2N.m. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative remote cable. 3. Using a trim stick (special tool #C-4755) or equivalent, gently pry switch up and out of mounting bracket. 4. Disconnect wire harness connector from hood ajar switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch in vehicle. 2. Connect wire harness connector to hood ajar switch. 3. Firmly snap hood ajar switch into mounting bracket. 4. Connect the battery negative remote cable. 5. Close hood. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 5623 Power Door Lock Switch: Testing and Inspection 1. Remove the switch from its mounting location, and disconnect from vehicle wiring harness. Door Lock Switch Resistance 2. Using an ohmmeter, refer to the table to determine if switch resistance is correct in the Lock and Unlock switch positions. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 5624 Power Door Lock Switch: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Power Mirror Switch (LHD) Power Mirror Switch (RHD) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 5628 Power Mirror Switch: Testing and Inspection 1. Remove power mirror switch. Mirror Switch Continuity (Part 1 Of 2) Mirror Switch Continuity (Part 2 Of 2) 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Continuity table 3. If test results are not obtained as shown in the Mirror Switch Continuity table, replace the switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 5629 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 5636 Sunroof / Moonroof Switch: Service and Repair CONTROL UNIT REMOVAL Fig. 1 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 5637 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 5638 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 (Fig. 1). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations The Vehicle Theft Security System (VTSS) Deck Lid Security Switch is mounted to the back of the deck lid lock cylinder. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 5642 Trunk / Liftgate Switch: Diagrams Decklid Release Switch (Power Release) Decklid Security Switch (Knock Out) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Decklid Release Switch Replacement Trunk / Liftgate Switch: Service and Repair Decklid Release Switch Replacement 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Decklid Release Switch Replacement > Page 5645 Trunk / Liftgate Switch: Service and Repair Decklid Security Switch Replacement 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 9 2. Remove the four nuts and remove the spoiler (Fig. 9). INSTALLATION 1. Install the spoiler and nuts. 2. Tighten nuts to 3 N.m (30 in.lbs.). 3. Install the decklid cover. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 holding cowl cover to cowl at base of windshield opening (Fig. 1). 4. Remove hood to cowl seal, at the leading edge of cowl cover. Pull the seal towards the front of the vehicle. 5. Separate the cowl cover from the vehicle. INSTALLATION 1. Place cowl panel in place on vehicle. 2. Install the five screws holding cowl panel to cowl at base of windshield opening. 3. Push the hood to cowl seal over the forward flange of the cowl cover and cowl plenum. 4. Install windshield wiper arms. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair B-PILLAR WEATHERSTRIP CHANNEL REMOVAL Fig. 1 1. Remove B-pillar applique (Fig. 1). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Front Door Window Glass Weatherstrip: Service and Repair Front Door 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-one 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5663 Front Door Window Glass Weatherstrip: Service and Repair FDR Glass Run Weatherstrip FOR 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. 2 6. Pull run weatherstrip from window frame channel (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5664 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. 3 3. Remove outer belt weatherstrip from vehicle (Fig. 3). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5665 Front Door Window Glass Weatherstrip: Service and Repair 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5666 Front Door Window Glass Weatherstrip: Service and Repair Front Door 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-one 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. FDR Glass Run Weatherstrip FOR 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. 2 6. Pull run weatherstrip from window frame channel (Fig. 2). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5667 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. Fig. 3 3. Remove outer belt weatherstrip from vehicle (Fig. 3). 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5668 FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 4 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. 4). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5669 Fig. 8 1. Using a fork-type prying tool, disengage push in fasteners attaching sill secondary weatherstrip to door (Fig. 8). 2. Remove weatherstrip from door. 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. 9 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 5670 2. Pull decklid weatherstrip form decklid opening fence (Fig. 9). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 4 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. 4). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 5675 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. 5 5. Pull run weatherstrip from window frame channel (Fig. 5). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Front/Rear Door Inner Belt Weatherstrip > Page 5676 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5681 Cruise Control Servo: Description and Operation 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 at 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 duty 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5682 Cruise Control Servo: Service and Repair REMOVAL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 5686 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the throttle cable cover. Fig.2 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. Speed Control Servo 7. Remove 2 nuts retaining bracket to servo. 8. Remove push nuts holding cable housing to servo. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 5687 Fig.4 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations The speed control switches are mounted in two separate switch pods on the steering wheel and are wired through the clockspring device under the airbag module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5691 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. 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, TAPUP 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 COAST, and CANCEL. Refer to the Speed Control 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. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5692 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are 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. 1. Turn OFF ignition. 2. Remove two screws from side of each switch. 3. Rock switch away from airbag and steering wheel. 4. Disconnect two-way electrical connector. 5. Repeat for the other switch. INSTALLATION The speed control switches are 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. 1. Install switches. 2. Connect two-way electrical connector. 3. Install two screws to the side of each switch. 4. Install airbag, refer to the Restraint Systems Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 5696 Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is located in the engine compartment. It is made of plastic. The reservoir stores engine vacuum. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 5697 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL 1. Remove the pass anger side cowl screen. Fig.6 Vacuum Reservoir Mounting 2. Remove vacuum reservoir mounting nuts. 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 5.6 Nm (50 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations The speed control switches are mounted in two separate switch pods on the steering wheel and are wired through the clockspring device under the airbag module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5702 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. 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, TAPUP 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 COAST, and CANCEL. Refer to the Speed Control 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. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5703 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are 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. 1. Turn OFF ignition. 2. Remove two screws from side of each switch. 3. Rock switch away from airbag and steering wheel. 4. Disconnect two-way electrical connector. 5. Repeat for the other switch. INSTALLATION The speed control switches are 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. 1. Install switches. 2. Connect two-way electrical connector. 3. Install two screws to the side of each switch. 4. Install airbag, refer to the Restraint Systems Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Application and ID 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Application and ID > Page 5708 ABS Light: Description and Operation For Description and Operation of this Component refer to Brakes, Antilock Brake System, Description and Operation, Antilock Brake System Component Description. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer Audible Warning Device: Description and Operation Chime/Buzzer 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 always illuminate the seat belt reminder lamp for four to eight seconds when the ignition switch is turned to the ON position. The CHIME will sound during the same time interval if the driver's seat belt is not fastened. Passenger belts are not connected to the system. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer > Page 5714 Audible Warning Device: Description and Operation Seat Belt Reminder System 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 always illuminate the seat belt reminder lamp for four to eight seconds when the ignition switch is turned to the ON position. The CHIME will sound during the same time interval if the driver's seat belt is not fastened. Passenger belts are not connected to the system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 5715 Audible Warning Device: Testing and Inspection 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Application and ID Brake Warning Indicator: Application and ID 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Application and ID > Page 5719 Brake Warning Indicator: Testing and Inspection 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Use Wiring Diagrams 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 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. 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 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 function only. Circuit Functions 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 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, Ground and Splice Information 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: 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 - 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. 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. - 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 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 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. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 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. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color 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 a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 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. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire 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. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge 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. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 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. 26). Special Tools Probing Tool Package 6807 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Cigarette Lighter: Diagnostic Aids 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 5742 Cigarette Lighter: Service and Repair REMOVAL Fig.3 Battery Negative Cable Remove/Install 1. Disconnect and isolate the battery negative cable (Fig. 3). 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 5743 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5748 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 5752 Door Switch: Diagrams Driver Door Ajar Switch Driver Door Lock Motor/Ajar Switch Hood Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 5753 Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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..................................................................................................................... ...............................................................PC194 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 5760 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 5761 Fuel Gauge Sender: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 5762 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5767 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Application and ID Instrument Panel Bulb: Application and ID CAUTION: Do not use bulbs other than those listed in the chart below. Damage to lamp can result. Bulb Application Instrument Cluster Illumination............................................................................................................. ...............................................................PC194 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Application and ID > Page 5771 Instrument Panel Bulb: Testing and Inspection Every time the vehicle is switched to the START/RUN position, the cluster goes through a BULB CHECK. This tests most of the indicator lamps and Vacuum Fluorescent (VF) displays. If only one lamp is out, remove the instrument cluster and replace the defective bulb or Light Emitting Diode (LED). If some or all of the lamps fail to light, refer to the proper Body Diagnostics Procedures. Fig.1 Base Instrument Cluster Without Tachometer Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Application and ID > Page 5772 Fig.2 Premium Instrument Cluster With Tachometer To diagnose the cluster lamps first place the cluster in self-diagnostic mode. With the ignition switch in the OFF position, press the trip odometer reset button down. Simultaneously turn the ignition key to the ON position and release the trip reset button. All the indicator lamps and VF displays should illuminate except for the fog lamp, turn signal, and high beam select indicators. Refer to (Fig. 1) and (Fig. 2). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Application and ID > Page 5779 Malfunction Indicator Lamp: Description and Operation 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 5783 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Description and Operation Oil Pressure Sender: Description and Operation DESCRIPTION The oil pressure switch is located on the right rear side of the engine block (Fig. 118). 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 PSI and 4 PSI. The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure, within a maximum of 3 PSI of the switch's "Closed" circuit pressure point. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Description and Operation > Page 5787 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. 119). INSTALLATION 1. Install oil pressure switch and connect electrical connector (Fig. 119). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID > Page 5791 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The low oil pressure warning lamp Will illuminate when the ignition switch is turned to the ON position without engine running. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. Fig.4 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. 4). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Testing and Inspection Parking Brake Warning Lamp: Testing and Inspection 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation 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 always illuminate the seat belt reminder lamp for four to eight seconds when the ignition switch is turned to the ON position. The CHIME will sound during the same time interval if the driver's seat belt is not fastened. Passenger belts are not connected to the system. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 5805 Door Switch: Diagrams Driver Door Ajar Switch Driver Door Lock Motor/Ajar Switch Hood Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 5806 Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 5810 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 5811 Fuel Gauge Sender: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 5812 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Application and ID > Page 5819 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Back-Up Lamp Switch 18 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications > Page 5825 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 backup 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. Tighter switch to 24 Nm (18 ft. lbs.) torque. CAUTION: Do not over tighten switch. 2. Connect back-up lamp switch connector. 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Application and ID Brake Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the chart 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 - P2717W Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5832 Brake Lamp Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5833 Brake Light Switch: Description and Operation 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 is 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5834 Brake Light Switch: Testing and Inspection NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. If misadjusted, replace the switch. It cannot be readjusted. 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.1 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.2 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, do not reinstall it, replace the switch. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5835 Brake Light Switch: Service and Repair 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. Discard the brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. 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. 1. Mount and adjust the NEW brake lamp switch using the following procedure: a. Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. b. When the switch is fully seated in its bracket, rotate the switch clockwise approximately 300 to lock the switch into place. Fig.5 Adjustment Lever Movement c. With the brake pedal in the fully released position, move the lever on the back of the brake lamp switch from the angled non-adjusted position to the full vertical position as shown. This will adjust the brake lamp switch to the vehicle. 2. Reconnect the battery negative terminal. 3. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 4. Road test the vehicle to ensure proper operation of the brakes including ABS if equipped. and speed control if equipped. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Application and ID 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Application and ID Center Mounted Brake Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the chart 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 CHMSL 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement > Page 5844 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. CHMSL Lamp 3. Remove screws 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 screws attaching center high mounted stop lamp to deck lid 3. Install socket and bulb from lamp. 4. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMP MODULE Vehicles built for use in Canada are equipped with a Daytime Running Lamp (DRL) system. The DRL function is provided by the cluster. The DRL Module is an integral part of the instrument panel cluster. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 5862 Door Switch: Diagrams Driver Door Ajar Switch Driver Door Lock Motor/Ajar Switch Hood Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 5863 Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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..................................................................................................................... ...............................................................PC194 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations 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. Fig.8 Combination Flasher Location The flasher is mounted to the back side of the multi-function switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 5872 Hazard Warning Flasher: Description and Operation 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 90 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 multi-function 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 multi-function switch on the steering column. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 5873 Hazard Warning Flasher: Service and Repair Fig.8 Combination Flasher Location REMOVAL 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 multi-function 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations The integrated switch assembly is mounted to the left hand side of the steering column. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 5877 Multi-Function Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 5878 Hazard Warning Switch: Description and Operation Fig.17 Multi-function Switch MULTI-FUNCTION SWITCH The turn signals are part of the multi-function switch, which contains: Electrical circuitry for turn signals. - Hazard warning switch. - Headlamp switch. - Fog Lamp Switch. - Headlamp beam select switch. - Optical Horn. - Instrument Panel Lamp Dimmer/Interior Lamp Switch. - Combination Flasher. Hazard Warning System The hazard warning system is actuated by a push button located in the multi-function switch on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on front of the button. The hazard warning system allows the vehicle operator to provide the drivers of other vehicles in near proximity an optical indication that the vehicle is disabled or is an obstacle to traffic flow. Unlike the turn signal system, the hazard warning system has battery current at all times, regardless of ignition switch position. When the hazard warning system is activated, the combination flasher will cause both the right and left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear turn signal lamps to flash ON and OFF. If the exterior lamps are turned OFF; the front park/turn signal lamps and the front side marker lamps will flash in unison. If the exterior lamps are turned ON, the front park/turn signal lamps and the side marker lamps will flash alternately. Multi-function Switch The integrated switch assembly is mounted to the left hand side of the steering column. When the driver wishes to signal his intentions to change direction of travel, he moves the lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position, a canceling cam molded to the clockspring mechanism comes in contact with the cancel actuator on the turn signal multi-function switch assembly. The cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Fig.17 Multi-function 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 5883 Headlamp Leveling Switch (Built-Up-Export) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 5884 Headlamp Switch: Description and Operation Fig.17 Multi-function Switch The headlamp switch is integral to the left stalk of the multi-function switch. located on the steering column behind the steering wheel. A knob on the end of the left control stalk controls all of the exterior lighting functions. Turn the end of the control lever to the first detent for parking light operation. Turn to the second detent for headlight operation. To activate the front fog lights, turn ON the parking lights or the low beam headlights and pull out the end of the control lever. The headlamp switch is part of the multi-function switch . Refer to Electrical, Lamps/Lighting Exterior, Multi-Function Switch, Diagnosis and Testing, The headlamp switch cannot be repaired. If found defective, it must be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 5892 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 5893 Horn Relay: Diagrams Power Distribution Center Horn Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 5894 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, refer to Wiring Diagrams. 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 - 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.4 Horn Relay 5. Check relay for 70 to 75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 5895 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.5 Power Distribution Center (PDC) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 5899 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 5900 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 5901 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 5902 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Application and ID License Plate Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the chart 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.15 License Plate Lamp 2. Remove screws attaching license plate lamp to rear bumper. 3. Remove lamp from bumper. 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. 5. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement > Page 5908 License Plate Lamp: Service and Repair License Plate Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.15 License Plate Lamp 2. Remove screws attaching license plate lamp to rear bumper. 3. Remove lamp from bumper. 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. 4. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Application and ID Marker Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the chart 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 2. Reach behind front bumper fascia forward of front wheel and remove attaching clip from the front side marker lamp. 3. Remove bulb from socket. INSTALLATION 1. Install bulb into socket. 2. Install attaching clip to the front side marker lamp. 3. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Marker Lamp Replacement > Page 5917 Marker Lamp: Service and Repair Marker Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind front bumper fascia forward of front wheel and remove attaching clip from the front side marker lamp. 3. Remove bulb from socket. 4. Remove lamp. INSTALLATION 1. Place lamp into position. 2. Install bulb into socket. 3. Install attaching clip to the front side marker lamp. 4. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Application and ID Parking Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the chart 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-10-2 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 5925 8w-10-3 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 5926 Horn Relay: Diagrams Power Distribution Center Horn Relay Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 5927 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, refer to Wiring Diagrams. 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 - 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.4 Horn Relay 5. Check relay for 70 to 75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 5928 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.5 Power Distribution Center (PDC) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Back-Up Lamp Switch 18 ft.lb Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 5933 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 backup 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. Tighter switch to 24 Nm (18 ft. lbs.) torque. CAUTION: Do not over tighten switch. 2. Connect back-up lamp switch connector. 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Fig.2 Brake Lamp Switch The brake lamp switch is located under the instrument panel, at the brake pedal arm. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5937 Brake Lamp Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5938 Brake Light Switch: Description and Operation 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 is 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 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5939 Brake Light Switch: Testing and Inspection NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. If misadjusted, replace the switch. It cannot be readjusted. 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.1 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.2 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, do not reinstall it, replace the switch. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5940 Brake Light Switch: Service and Repair 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. Discard the brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. 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. 1. Mount and adjust the NEW brake lamp switch using the following procedure: a. Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. b. When the switch is fully seated in its bracket, rotate the switch clockwise approximately 300 to lock the switch into place. Fig.5 Adjustment Lever Movement c. With the brake pedal in the fully released position, move the lever on the back of the brake lamp switch from the angled non-adjusted position to the full vertical position as shown. This will adjust the brake lamp switch to the vehicle. 2. Reconnect the battery negative terminal. 3. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 4. Road test the vehicle to ensure proper operation of the brakes including ABS if equipped. and speed control if equipped. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Turn Signal And Hazard Warning Flasher Diagnosis (Part 1 Of 2) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 5944 Turn Signal And Hazard Warning Flasher Diagnosis (Part 2 Of 2) FLASHER DIAGNOSIS Should any function of the multi-function switch fail, the entire switch assembly must be replaced. SWITCH DIAGNOSIS To test the switch: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 5945 Fig.21 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shrouds. 3. Disconnect the switch connector. Fig.18 Combination Flasher Connector(A) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 5946 Fig.19 Multi-Function Switch Connector (B) Fig.20 Windshield Wiper/Washer Switch Connector (C) Multi-Function Switch Continuity Test Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 5947 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. Refer to,, and for connector terminal locations. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 5948 Combination Switch: Service and Repair REMOVAL Fig.21 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove both upper and lower steering column shrouds. Fig.22 Multi-Function Switch Remove/Install 3. Disconnect both posi-lock harness connectors at the rear of the multi-function switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 5949 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. Install both upper and lower steering column shrouds. 6. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 5953 Door Switch: Diagrams Driver Door Ajar Switch Driver Door Lock Motor/Ajar Switch Hood Ajar Switch Left Rear Door Block Motor/Ajar Switch Passenger Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 5954 Right Rear Door Lock Motor/Ajar Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations The integrated switch assembly is mounted to the left hand side of the steering column. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 5961 Multi-Function Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 5962 Hazard Warning Switch: Description and Operation Fig.17 Multi-function Switch MULTI-FUNCTION SWITCH The turn signals are part of the multi-function switch, which contains: Electrical circuitry for turn signals. - Hazard warning switch. - Headlamp switch. - Fog Lamp Switch. - Headlamp beam select switch. - Optical Horn. - Instrument Panel Lamp Dimmer/Interior Lamp Switch. - Combination Flasher. Hazard Warning System The hazard warning system is actuated by a push button located in the multi-function switch on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on front of the button. The hazard warning system allows the vehicle operator to provide the drivers of other vehicles in near proximity an optical indication that the vehicle is disabled or is an obstacle to traffic flow. Unlike the turn signal system, the hazard warning system has battery current at all times, regardless of ignition switch position. When the hazard warning system is activated, the combination flasher will cause both the right and left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear turn signal lamps to flash ON and OFF. If the exterior lamps are turned OFF; the front park/turn signal lamps and the front side marker lamps will flash in unison. If the exterior lamps are turned ON, the front park/turn signal lamps and the side marker lamps will flash alternately. Multi-function Switch The integrated switch assembly is mounted to the left hand side of the steering column. When the driver wishes to signal his intentions to change direction of travel, he moves the lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position, a canceling cam molded to the clockspring mechanism comes in contact with the cancel actuator on the turn signal multi-function switch assembly. The cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Fig.17 Multi-function 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 5966 Headlamp Leveling Switch (Built-Up-Export) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 5967 Headlamp Switch: Description and Operation Fig.17 Multi-function Switch The headlamp switch is integral to the left stalk of the multi-function switch. located on the steering column behind the steering wheel. A knob on the end of the left control stalk controls all of the exterior lighting functions. Turn the end of the control lever to the first detent for parking light operation. Turn to the second detent for headlight operation. To activate the front fog lights, turn ON the parking lights or the low beam headlights and pull out the end of the control lever. The headlamp switch is part of the multi-function switch . Refer to Electrical, Lamps/Lighting Exterior, Multi-Function Switch, Diagnosis and Testing, The headlamp switch cannot be repaired. If found defective, it must be replaced. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 5971 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 5972 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 5973 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 5974 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 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 5978 Turn Signal Switch: Description and Operation Fig.17 Multi-function Switch MULTI-FUNCTION SWITCH The turn signals are part of the multi-function switch, which contains: Electrical circuitry for turn signals. - Hazard warning switch. - Headlamp switch. - Fog Lamp Switch. - Headlamp beam select switch. - Optical Horn. - Instrument Panel Lamp Dimmer/Interior Lamp Switch. - Combination Flasher. Hazard Warning System The hazard warning system is actuated by a push button located in the multi-function switch on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on front of the button. The hazard warning system allows the vehicle operator to provide the drivers of other vehicles in near proximity an optical indication that the vehicle is disabled or is an obstacle to traffic flow. Unlike the turn signal system, the hazard warning system has battery current at all times, regardless of ignition switch position. When the hazard warning system is activated, the combination flasher will cause both the right and left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear turn signal lamps to flash ON and OFF. If the exterior lamps are turned OFF; the front park/turn signal lamps and the front side marker lamps will flash in unison. If the exterior lamps are turned ON, the front park/turn signal lamps and the side marker lamps will flash alternately. Multi-function Switch The integrated switch assembly is mounted to the left hand side of the steering column. When the driver wishes to signal his intentions to change direction of travel, he moves the lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position, a canceling cam molded to the clockspring mechanism comes in contact with the cancel actuator on the turn signal multi-function switch assembly. The cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Application and ID Tail Lamp: Application and ID CAUTION: Do not use bulbs other than the bulb listed in the chart 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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.23 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement > Page 5984 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. Fig.24 Tail And Stop Lamp 3. Remove nuts attaching tail lamp to the rear closure panel. 4. Remove lamp housing from vehicle. INSTALLATION 1. Place lamp housing into position. 2. Install nuts attaching tail lamp to the rear closure panel. 3. Reposition trunk lining to rear closure panel. 4. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair Trunk Lamp: Service and Repair 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection Turn Signal And Hazard Warning Flasher Diagnosis (Part 1 Of 2) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 5992 Turn Signal And Hazard Warning Flasher Diagnosis (Part 2 Of 2) FLASHER DIAGNOSIS Should any function of the multi-function switch fail, the entire switch assembly must be replaced. SWITCH DIAGNOSIS To test the switch: Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 5993 Fig.21 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shrouds. 3. Disconnect the switch connector. Fig.18 Combination Flasher Connector(A) Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 5994 Fig.19 Multi-Function Switch Connector (B) Fig.20 Windshield Wiper/Washer Switch Connector (C) Multi-Function Switch Continuity Test Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 5995 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. Refer to,, and for connector terminal locations. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 5996 Combination Switch: Service and Repair REMOVAL Fig.21 Disconnect And Isolate Battery Negative Cable 1. Disconnect and isolate the battery negative cable. 2. Remove both upper and lower steering column shrouds. Fig.22 Multi-Function Switch Remove/Install 3. Disconnect both posi-lock harness connectors at the rear of the multi-function switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 5997 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. Install both upper and lower steering column shrouds. 6. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations 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. Fig.8 Combination Flasher Location The flasher is mounted to the back side of the multi-function switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 6001 Turn Signal Flasher: Description and Operation 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 90 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 multi-function 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 multi-function switch on the steering column. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 6002 Turn Signal Flasher: Service and Repair Fig.8 Combination Flasher Location REMOVAL 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 multi-function 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6009 Turn Signal Switch: Description and Operation Fig.17 Multi-function Switch MULTI-FUNCTION SWITCH The turn signals are part of the multi-function switch, which contains: Electrical circuitry for turn signals. - Hazard warning switch. - Headlamp switch. - Fog Lamp Switch. - Headlamp beam select switch. - Optical Horn. - Instrument Panel Lamp Dimmer/Interior Lamp Switch. - Combination Flasher. Hazard Warning System The hazard warning system is actuated by a push button located in the multi-function switch on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on front of the button. The hazard warning system allows the vehicle operator to provide the drivers of other vehicles in near proximity an optical indication that the vehicle is disabled or is an obstacle to traffic flow. Unlike the turn signal system, the hazard warning system has battery current at all times, regardless of ignition switch position. When the hazard warning system is activated, the combination flasher will cause both the right and left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear turn signal lamps to flash ON and OFF. If the exterior lamps are turned OFF; the front park/turn signal lamps and the front side marker lamps will flash in unison. If the exterior lamps are turned ON, the front park/turn signal lamps and the side marker lamps will flash alternately. Multi-function Switch The integrated switch assembly is mounted to the left hand side of the steering column. When the driver wishes to signal his intentions to change direction of travel, he moves the lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position, a canceling cam molded to the clockspring mechanism comes in contact with the cancel actuator on the turn signal multi-function switch assembly. The cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Application and ID > Page 6016 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations Rear Window Defogger Switch: Locations Rear Window Defogger Switch Location The rear window defogger switch is a control switch and timing circuit integrated into a single panel mounted assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 6022 Rear Window Defogger Switch: Description and Operation Rear Window Defogger Switch Location The rear window defogger switch is a control switch and timing circuit integrated into a single panel mounted assembly. Actuating the switch energizes the circuit which allows current to flow through the grid lines. Upon initial actuation for approximately eight to ten minutes, or until either the switch or ignition is turned OFF. An indicating lamp illuminates a Light Emitting Diode (LED) inlaid in the control switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 6023 Rear Window Defogger 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. 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 6024 3. Follow the same procedures used for IN-VEHICLE TESTING, except for step Step 2. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations Rear Window Defogger Switch: Locations Rear Window Defogger Switch Location The rear window defogger switch is a control switch and timing circuit integrated into a single panel mounted assembly. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 6029 Rear Window Defogger Switch: Description and Operation Rear Window Defogger Switch Location The rear window defogger switch is a control switch and timing circuit integrated into a single panel mounted assembly. Actuating the switch energizes the circuit which allows current to flow through the grid lines. Upon initial actuation for approximately eight to ten minutes, or until either the switch or ignition is turned OFF. An indicating lamp illuminates a Light Emitting Diode (LED) inlaid in the control switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 6030 Rear Window Defogger 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. 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. 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Locations > Page 6031 3. Follow the same procedures used for IN-VEHICLE TESTING, except for step Step 2. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Power Window Switch Continuity Remove the switch from its mounting, (Refer to ELECTRICAL/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 results are not obtained, replace the switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 6035 Power Window Switch: Service and Repair Battery Negative Cable Remove/Install 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 Battery Negative Cable Remove/Install 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Power Window Switch Continuity Remove the switch from its mounting, (Refer to ELECTRICAL/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 results are not obtained, replace the switch. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 6044 Power Window Switch: Service and Repair Battery Negative Cable Remove/Install 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair BACKLITE REMOVAL 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 REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND 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 Windshield for a description of tools and adhesive systems that are recommended for use in this procedure. 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. Refer to Windshield for proper procedures. 5. Remove the rear window from the vehicle. INSTALLATION 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 REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND 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 Windshield for a description of tools and adhesive systems that are recommended for use in this procedure. 1. Prepare the work area, window fence, and glass the same way as described in the Windshield section of this group. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 6049 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 section of this group (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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Front Door Window Glass Weatherstrip: Service and Repair Front Door 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-one 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6055 Front Door Window Glass Weatherstrip: Service and Repair FDR Glass Run Weatherstrip FOR 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. 2 6. Pull run weatherstrip from window frame channel (Fig. 2). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6056 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. 3 3. Remove outer belt weatherstrip from vehicle (Fig. 3). INSTALLATION 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6057 Front Door Window Glass Weatherstrip: Service and Repair 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6058 Front Door Window Glass Weatherstrip: Service and Repair Front Door 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-one 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. FDR Glass Run Weatherstrip FOR 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. 2 6. Pull run weatherstrip from window frame channel (Fig. 2). Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6059 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. Fig. 3 3. Remove outer belt weatherstrip from vehicle (Fig. 3). 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 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6060 FRONT/REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Fig. 4 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. 4). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6061 Fig. 8 1. Using a fork-type prying tool, disengage push in fasteners attaching sill secondary weatherstrip to door (Fig. 8). 2. Remove weatherstrip from door. 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. 9 Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door > Page 6062 2. Pull decklid weatherstrip form decklid opening fence (Fig. 9). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 4 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. 4). INSTALLATION 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 6068 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. 5 5. Pull run weatherstrip from window frame channel (Fig. 5). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 6069 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 12 2. Slide a window crank removal tool behind the window crank to release crank handle lock clip (Fig. 12). 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REMOVAL 1. Remove door trim panel. 2. Remove door glass from regulator channel. Rear Door Glass 3. Loosen screws attaching window regulator channel and crank housing to door panel. 4. Disengage screw and bolt heads from keyhole slots in door panel. 5. Loosen bolts attaching window regulator to door panel. 6. Disengage regulator from door panel, and crank housing. 7. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel, 8. 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. Position glass to regulator roller channel. 6. Tighten fasteners attaching door glass to roller channel. 7. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6078 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Remove door glass from regulator channel. Fig. 3 3. Loosen screws attaching window regulator channel and crank housing to door panel (Fig. 3). 4. Disengage screw and bolt heads from keyhole slots in door panel. 5. Loosen bolts attaching window regulator to door panel. 6. Disengage regulator from door panel, and crank housing. 7. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. 8. 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. Position glass to regulator roller channel. 6. Tighten fasteners attaching door glass to roller channel. 7. Install door trim panel. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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-one 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 6085 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 6086 Fig. 2 5. Remove windshield A-pillar moldings (Fig. 2) using a suitable hook tool and trim stick. 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. 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 equipment being used. 6. Remove windshield from vehicle. INSTALLATION Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 6087 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 6088 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 3. Remove the left side cowl cover. Refer to Body, Exterior, Cowl Cover, Removal. 4. Disconnect the motor posi-lock harness connector. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Page 6094 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 to 9 Nm (60 to 80 in. lbs.) torque. 3. Connect the motor posi-lock harness connector. 4. Install the left side cowl cover. 5. Install the wiper arms. 6. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair REMOVAL 1. Remove the Multi-Function Switch from the vehicle. Fig.15 Wiper/washer Switch 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 to the windshield washer pump from the reservoir. INSTALLATION 1. Install the windshield washer pump into the reservoir. 2. Install the two fasteners retaining speed control vacuum reservoir. 3. Install the reservoir through fender opening. 4. Install the fasteners to the reservoir. Tighten the reservoir screws to 6.8 to 8.3 Nm (60 to 75 in. lbs.) torque. 5. Connect the washer hose at the pump and fill the reservoir. 6. Connect the wire connector to the reservoir pump. 7. Lower vehicle from hoist. 8. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation 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 aimed, 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 6111 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 adjust as necessary. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair REMOVAL 1. Remove the Multi-Function Switch from the vehicle. Fig.15 Wiper/washer Switch 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. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 6118 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. 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6132 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6133 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement > Page 6136 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 R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 3. Remove the left side cowl cover. Refer to Body, Exterior, Cowl Cover, Removal. 4. Disconnect the motor posi-lock harness connector. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Service and Repair > Page 6140 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 to 9 Nm (60 to 80 in. lbs.) torque. 3. Connect the motor posi-lock harness connector. 4. Install the left side cowl cover. 5. Install the wiper arms. 6. Connect the battery negative cable. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection Wiper Motor: Testing and Inspection Wiper Motor Test Whenever a wiper motor malfunction occurs, verify that the wire harness is properly connected, then start normal diagnosis and repair procedures. Refer to the table. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Page 6144 Wiper Motor: Service and Repair REMOVAL 1. Remove wiper module. 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 For installation and reverse the above procedures. 1. Attach motor to linkage. Install the three motor mounting screws and tighten the motor mounting screws to 5 to 6 Nm (45 to 55 in. lbs.) torque. NOTE: If motor crank was taken oft for any reason, install and tighten drive link nut to 11 to 12 Nm (98 to 106 in. lbs.) torque. 2. Add unilube grease to the linkage socket and install the linkage onto the motor crank. 3. Install the wiper module. Dodge Neon R Workshop Manual (R-T L4-2.0L VIN F HO (2001)) 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. 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.